US011207611B1

( 12) United States Patent ( 10 ) Patent No.: US 11,207,611 B1

Becker et al . (45 ) Date of Patent : Dec. 28 , 2021
( 54 ) PROCESS FOR SEPARATING (52 ) U.S. CI.
HYDROCARBONS IN A LIQUID FEED CPC B01D 3/141 (2013.01 ) ; B01D 3/007
UTILIZING AN EXTERNALLY HEATED ( 2013.01 ) ; B01D 3/32 (2013.01 ) ; B01D 5/006
REBOILER CONNECTED TO A DIVIDED (2013.01 ) ; B01D 5/0039 ( 2013.01 ) ; BOLD
WALL COLUMN AS THE PRIMARY 5/0075 ( 2013.01 ) ; C07C 7/04 ( 2013.01 ) ; CIOG
SOURCE OF HEAT ENERGY 7700 ( 2013.01 ) ; CIOG 2300/1025 ( 2013.01 ) ;
CIOG 2400/28 ( 2013.01 )
( 71 ) Applicant: BURNS & McDONNELL ( 58 ) Field of Classification Search
ENGINEERING COMPANY, INC . , None
Kansas City, MO (US ) See application file for complete search history.
( 72 ) Inventors: Andrew Becker , Westwood, KS (US ); (56 ) References Cited
Curt Hemphill , Overland Park , KS U.S. PATENT DOCUMENTS
(US ) ; Christopher Niemeyer ,
Kingwood, TX (US ); Edward McCoy, 3,034,307 A * 5/1962 Berger BOID 3/4227
Overland Park , KS (US ) 62/628
4,230,533 A 10/1980 Giroux
( 73 ) Assignee : BURNS & MCDONNELL 4,773,968
5,457,277
A
A
9/1988 O'Connell et al .
10/1995 Sy
ENGINEERING COMPANY, INC . , 6,077,985 A 6/2000 Stork
Kansas City, MO (US ) 6,291,734 B1 9/2001 Stork
6,347,533 B1 2/2002 Tung
( * ) Notice: Subject to any disclaimer, the term of this 6,540,907 B1 4/2003 Towler et al .
patent is extended or adjusted under 35 (Continued )
U.S.C. 154 ( b ) by 74 days.
FOREIGN PATENT DOCUMENTS
( 21 ) Appl . No .: 16 /459,894
WO WO 2016128110 A1 8/2016
(22) Filed : Jul . 2 , 2019 Primary Examiner Derek N Mueller
(74 ) Attorney, Agent, or Firm Stinson LLP
Related U.S. Application Data
( 60 ) Provisional application No. 62 / 693,638 , filed on Jul . (57 ) ABSTRACT
3 , 2018 . The present invention is directed to a system and process for
fractionating a hydrocarbon liquid feed using a single divid
( 51 ) Int . Ci. ing wall column ( DWC ) , an externally heated reboiler
B01D 3/14 ( 2006.01) connected to the DWC , and a deisobutanizer ( DIB ) inte
C10G 7700 ( 2006.01 ) grated with a compressor. The majority of all externally
C07C 7/04 ( 2006.01 ) supplied heat energy supplied to the system is input to the
BOID 5/00 ( 2006.01 ) system via the externally heated reboiler of the DWC .
B01D 3/32 ( 2006.01 )
B01D 3/00 ( 2006.01 ) 13 Claims , 3 Drawing Sheets
wale
3312 3311
Condenser
3303 35014
3308 3516
Cornpressex 3504
DWC 112
Daproparizeri
Detsutamize 132 Dersebutorata $ 46 3507
3302 C3 3502
3307 2308
118
182
116 ICA
NSL (HEM ) 3501 168 3508
3301

120
Condensexi
Retrotter
3310 3510 1505
Reboder 140
3314
3305
148 358
3309 3503 N - C4
3333
3801.
C5 +
3701
 US 11,207,611 B1
Page 2

( 56 ) References Cited 9,504,934 B2 11/2016 Agrawal et al.

9,683,776 B2 6/2017 Stylianou et al.
U.S. PATENT DOCUMENTS 9,724,619 B2 8/2017 Bhargava et al .
9,895,624 B2 2/2018 Lee et al .
6,551,465 B1 4/2003 Van Zile et al. 9,938,205 B2 4/2018 Du et al .
6,726,835 B2 4/2004 Towler et al . 10,005,002 B2 6/2018 Gao et al .
6,927,314 B1 8/2005 Schultz et al . 10,106,476 B1 10/2018 Kockler
7,169,267 B2 1/2007 Kaibel et al . 2007/0227875 A1 10/2007 Kammerhofer
7,249,469 B2 7/2007 Porter 2012/0141333 A1 6/2012 Ulas et al .
7,264,696 B2 9/2007 Kaibel et al . 2012/0149957 A1 6/2012 Krupa et al .
7,422,197 B2 9/2008 Zone et al. 2013/0213088 A1 * 8/2013 Stylianou C10L 3/101
7,437,891 B2 10/2008 Reyneke et al. 62/630
7,462,277 B2 12/2008 Adrian et al. 2014/0171717 A1 * 6/2014 Sinha B01D 3/143
7,528,290 B2 5/2009 Zimmermann et al . 585/802
7,556,717 B2 7/2009 Heida 2014/0231238 A1 8/2014 Bhargava et al .
7,649,108 B2 1/2010 Schal et al .
7,691,239 B2 4/2010 Kister et al . 2014/0262740 A1 9/2014 McCaulley
7,763,165 B1 7/2010 Schultz 2015/0041308 Al 2/2015 Lee et al .
8,007,661 B1 8/2011 Schultz et al . 2015/0052938 A1 2/2015 Bauer et al.
8,092,655 B2 1/2012 Burst et al . 2015/0251972 A1 9/2015 Shecterle et al .
8,178,060 B2 5/2012 Corradi 2016/0102032 Al 4/2016 Du et al .
8,323,457 B2 12/2012 Townsend 2017/0029348 A1 2/2017 Bender
8,480,860 B2 7/2013 Kovak 2017/0239589 A1 8/2017 Spriewald
8,562,792 B2 10/2013 King 2018/0154278 A1 6/2018 Lee et al .
8,747,654 B2 6/2014 Ulas et al . 2018/0178141 A1 6/2018 Lee et al .
8,771,479 B2 7/2014 Lee et al . 2018/0216011 Al 8/2018 Phu
8,845,864 B2 9/2014 Lee et al .
9,309,169 B2 4/2016 Ou et al . * cited by examiner
U.S. Patent Dec. 28 , 2021 Sheet 1 of 3 US 11,207,611 B1

2808
2534
2607 58

Compres x
V2
82

Condes Rebuie 2505

2510
NA 2601
2522
48

2506
kasbutnze 2502
43

2701

04 2501
C3 2308 1
.
FIG

Waterls
Ehas e2 08 231 2304
2307

0
2312 2303
Condes 2396 32
3

%
220

Condesr Rehigrant2 1
2212 2 03
2207
OWC DepanizeDrtanizer 2302
18

*
3

2303
2310
2309

2206
Retroer 23052314 213
28
Detlarg2 02 22
24

Feed
NGL
Etrane
W
(
)
2 81
U.S. Patent Dec. 28 , 2021 Sheet 2 of 3 US 11,207,611 B1

14 3508
3504
3507 158
358

Compreso Cand sReboder3505

%
18

112 3901
? 3510
146

3508
Deisobutarzk 3502
3701
2
.
FIG

C4 3501
3 03
Water
A831
/ 3 04
3 07 116 120 140

Condesr 326
3 12 3 03
132
134

DeproaizdDebulanizer 3 02
18
$

3 10
3309

MGL
Ethase
No
(
)
3 01 Rebodn3 053 14 3 13
U.S. Patent Dec. 28 , 2021 Sheet 3 of 3 US 11,207,611 B1

-C4 4508

4504
4507 258
258

C/ondenserReboiler
Compreso
212
?
262

244 4510 4509

4603

246
4508
Desobutaizr A502
248
4701

04
FIG
3
.

Eusone4324 4308
Water
/Air 431
4323

Condesr Refrig ant

320
4322
4325
4323
4312 4303 Conckiser 4306
232
235
217 220
234

Deproaniz Debutanizr
OWC !De thance 4302 218 216 219 264

4310
308

*
C3

Rebos 43053 14 4313

Feed
NG
Edane
!
W
(
)
4201
 US 11,207,611 B1
1 2
PROCESS FOR SEPARATING on line in this industry, it is desirable for operating compa
HYDROCARBONS IN A LIQUID FEED nies to try to minimize capital investment, required plot
UTILIZING AN EXTERNALLY HEATED space , and operating expenses. This is often achieved by
REBOILER CONNECTED TO A DIVIDED adding fractionation trains to existing facilities to leverage
WALL COLUMN AS THE PRIMARY 5 existing infrastructure with access to NGL feed and under
SOURCE OF HEAT ENERGY ground storage for the storage of purity product (s ).
Existing NGL fractionation trains commonly employ a
CROSS - REFERENCE TO RELATED series of fractionation columns (deethanizer, depropanizer,
APPLICATIONS debutanizer, and deisobutanizer ( DIB ) ) , each producing a
10 purity product. These multiple fractionation units require
This application is based on and claims priority to U.S. significant capital costs to construct and operate ; can require
Provisional Application Ser. No. 62/ 693,638 , filed on Jul. 3 , anumber
large area of plot space ; and can require an increased
of personnel to operate, which in turn increases the
2018 , which is incorporated herein by reference in its
entirety. potential for injuries. While a variety of different alternative
15 NGL fractionation train configurations have been suggested
STATEMENT REGARDING FEDERALLY in the art, a need remains in the art for more cost - effective
SPONSORED RESEARCH OR DEVELOPMENT NGL fractionation trains that can be employed in new
facilities or in modifications to existing facilities .
Not applicable. 20 BRIEF SUMMARY OF THE INVENTION
STATEMENT REGARDING JOINT RESEARCH
AGREEMENT The present invention is directed to a system and process
for fractionating a liquid feed that includes hydrocarbons
Not applicable. (“ hydrocarbon liquid feed ” ) into one or more purity prod
25 ucts , wherein the system and process utilize a dividing wall
BACKGROUND OF THE INVENTION column ( DWC ) having one or more dividing walls , an
externally heated reboiler connected to the DWC , and a
1. Field of the Invention deisobutanizer ( DIB ) integrated with a compressor. The
majority of all externally supplied heat energy supplied to
The present invention is generally directed to the field of 30 the system is input to the system via the externally heated
separating hydrocarbons in aa liquid feed stream , and is more reboiler of the DWC . In a preferred embodiment, at least
particularly directed to a system and process for fractionat- 95 % of all externally supplied heat energy supplied to the
ing a hydrocarbon liquid feed stream utilizing a single system for the primary purpose of fractionation of the
dividing wall column ( DWC ) , an externally heated reboiler hydrocarbon in the hydrocarbon liquid feed is input to the
connected to the DWC , and a deisobutanizer integrated with 35 system via the externally heated reboiler of the DWC . In
a compressor. another preferred embodiment, at least 75 % of all externally
>

supplied heat energy supplied to the system for any and all
2. Description of Related Art purposes is input to the system via the externally heated
reboiler of the DWC . By inputting the majority of all
Natural gas liquid (NGL ), a type of hydrocarbon liquid 40 externally supplied heat energy to the system via the exter
feed stream , contains C2 + hydrocarbons separated from the nally heated reboiler of the DWC , the system and process
2

raw natural gas (NG) off the well heads in gas processing are much more energy efficient and cost effective than prior
plants . NGL is typically sent to fractionation facilities where art systems and processes using externally heated reboilers
the ethane, propane , isobutane, n -butane, and C5 + compo- for each column.
nents are separated from one another. The ethane, propane , 45 In a system according to a preferred embodiment of the
isobutane and n - butane components ( C2 - C4 ) are commonly invention , the DWC is connected to : an inlet for feeding the
sold for use as purity products and the C5 + component hydrocarbon liquid feed into the DWC ; an overhead outlet
( natural gasoline ) is sold as a low octane gasoline blend through which an overhead comprising C3 hydrocarbons
stock , diluent, or as a chemical feed such as feed to a steam may be removed from the DWC ; an intermediate outlet
cracker to produce ethylene, propylene , and other cracking 50 through which an intermediate comprising C4 hydrocarbons
byproducts. The amount, if any, of ethane in any given NGL may be removed from the DWC and fed to the DIB ; a
fractionation feed will vary greatly depending on the region / reboiler outlet and inlet connected to the externally heated
market, equipment limitations , and pipeline specifications. reboiler of the DWC through which at least a portion of the
For example , some gas plants may reject ethane into the bottoms in the DWC may be circulated to supply heat to the
mostly methane natural gas stream such that essentially no 55 DWC ; and a bottoms outlet through which a bottoms
ethane is contained in the NGL fractionation feed stream , comprising C5 + hydrocarbons may be removed from the
while others recover the ethane into the NGL feed or DWC as a product. The overhead outlet from the DWC may
fractionate ethane out into a relatively pure ethane product be connected to a condenser configured to condense the
using a deethanizer. In addition, some NGL fractionation overhead vapor, preferably using water, air, or a combination
feed streams carry a very low ethane concentration ( such as 60 thereof. The condenser may be connected to a condensed
in the northeast ), while others have high ethane concentra- overhead outlet though which at least a portion of the
tions ( such as seasonally in the gulf coast) . condensed overhead can be refluxed back to the DWC and
The NGL fractionation industry in the US has seen a through which the remaining condensed overhead may be
significant growth through the 2000s with the application of removed as a propane product.
horizontal drilling and fracturing technologies sparking sig- 65 In this system according to a preferred embodiment of the
nificant investment and more NGL production and fraction- invention , the DIB is connected to : an overhead outlet
ation . As new fractionation trains are designed and brought through which an overhead comprising iso - C4 may be
 US 11,207,611 B1
3 4
removed from the DIB ; a heat exchange outlet and inlet In a process according to a preferred embodiment of the
through which at least a portion of the bottoms of the DIB invention , the hydrocarbon liquid feed includes one or more
may be circulated through a heat exchange reboiler and C3 + hydrocarbons, and more preferably includes propane
returned to the DIB ; and a bottoms outlet through which a (C3 ) , butanes (C4 ) , and C5 + hydrocarbons. In some embodi
bottoms comprising n- C4 may be removed as an n - butane 5 ments, the hydrocarbon liquid feed also includes ethane (C2 )
product. The compressor is connected to the DIB overhead in sufficient quantities to produce an ethane product. The
outlet and configured to compress the overhead exiting the process includes the following steps : feeding the hydrocar
DIB overhead outlet and to feed the compressed overhead bon liquid feed to the DWC ; heating at least a portion of the
bottoms of the DWC via the external heat supply of the
through the heat exchange reboiler so as to condense the
DIB overhead and heat the bottoms circulating through the 10 externally
feeding an heated reboilercomprising
intermediate of the DWC to heat the DWC
C4 hydrocarbons from;
heat exchange reboiler to supply heat to the DIB . The heat the
exchange reboiler eliminates the need for an externally the DWC into the DIB ; compressing an overhead vapor of
heated reboiler (in addition to the externally heated reboiler pressor throughfeeding
DIB and the compressed overhead via a com
the heat exchange reboiler to condense the
connected to the DWC ) connected to the DIB to heat the
bottoms of the DIB . The heat exchange reboiler may be 15 overhead ; circulating at least a portion of the bottoms of the
DIB through the heat exchange reboiler and returning the
connected to a condensed overhead outlet through which a heated bottoms to the DIB to supply heat to the DIB ; and
portion of the condensed overhead can be refluxed back to recovering one or more products from the DWC and / or DIB ,
the DIB and through which the remaining condensed over- wherein the products are relatively pure C3 - C5 + hydrocar
head comprising iso - C4 may be removed as an isobutane 20 bons
product.
bons . and /or one or more combinations of those hydrocar
Where the hydrocarbon liquid feed comprises C2 + hydro- The process preferably includes recovering an overhead
carbons and there is a desire to produce an ethane product, comprising C3 hydrocarbons from the DWC as a propane
the system in accordance with a preferred embodiment may product; recovering the bottoms comprising C5 + hydrocar
additionally include aa deethanizer column thermally coupled 25 bons from the DWC as a C5 + product; recovering the
with other components of the system . In an exemplary overhead comprising iso - C4 from the DIB as an isobutane
embodiment, the deethanizer is thermally coupled with the product; and / or recovering the bottoms comprising n - C4
externally heated reboiler via the dividing wall column from the DIB as an n - butane product. In addition , recovering
( DWC ) such that the externally supplied heat input to the the overhead comprising C3 hydrocarbons from the DWC as
system via the externally heated reboiler of the DWC 30 a propane product preferably includes condensing the DWC
supplies the heat needed for operation of the deethanizer. overhead with a condenser using water, air and / or combi
The deethanizer does not need or have a separate externally nations thereof; optionally returning a portion of the over
heated reboiler dedicated to supplying heat directly to the head to the DWC as flux ; and removing the remaining
deethanizer. In this embodiment, the deethanizer is con- condensed overhead as a propane product.
nected to : an inlet for feeding the hydrocarbon liquid feed 35 In preferred embodiments, the propane product has a
into the deethanizer, an overhead outlet through which an purity of at least about 85 % , most preferably at least about
overhead comprising C2 hydrocarbons may be removed 95 % ; the C5 + product has a purity of at least about 90 % ,
from the deethanizer; and aa bottoms outlet through which a most preferably at least about 98 % ; the isobutane product
bottoms comprising C3 + hydrocarbons is fed from the has a purity of at least about 90% , most preferably at least
deethanizer into the DWC . The overhead outlet from the 40 about 96 % ; and / or the n - butane product has a purity of at
deethanizer may be connected to a condenser configured to least about 90 % , most preferably at least about 94 % .
condense the overhead , preferably using a refrigerant. The Where the hydrocarbon liquid feed includes C2 + and
condenser may be connected to aa condensed overhead outlet there is a desire to produce an ethane product, the process
though which at least a portion of the condensed overhead may utilize aa deethanizer to recover an ethane product from
can be refluxed back to the deethanizer and through which 45 the hydrocarbon liquid feed . This process additionally
the remaining condensed overhead comprising C2 hydro- includes feeding the hydrocarbon liquid feed containing C2
carbons may be removed as an ethane product. The DWC is hydrocarbons to the deethanizer column; recovering a
connected to a vapor outlet that extends from the DWC to deethanizer overhead comprising C2 hydrocarbons from the
the bottom section of the deethanizer. The vapor outlet is deethanizer column as an ethane product; feeding a deethan
configured to supply heat in the form of vapor from the 50 izer bottoms comprising C3 + hydrocarbons to the DWC ;
DWC to the deethanizer. and heating the deethanizer via thermally coupling the
Where the hydrocarbon liquid feed comprises C2 + hydro- deethanizer with the externally heated reboiler of the DWC .
carbons and there is a desire to produce an ethane product, The step of recovering the overhead comprising C2 hydro
an alternative system in accordance with a preferred carbons from the deethanizer as an ethane product may
embodiment utilizes the DWC (preferably having two divid- 55 include condensing the deethanizer overhead with a con
ing walls ) as a deethanizer, in addition to serving as a denser, preferably using a refrigerant; optionally returning a
depropanizer and debutanizer. In this embodiment, the DWC portion of the condensed overhead to the deethanizer as
is additionally connected to a second overhead outlet reflux ; and removing the remaining condensed overhead as
through which overhead comprising C2 hydrocarbons may an ethane product. In addition , the step of heating the
be removed from the DWC . This second overhead outlet 60 deethanizer preferably includes feeding a vapor from the
may be connected to aa condenser configured to condense the DWC to a bottom portion of the deethanizer to thereby heat
overhead , preferably using a refrigerant. The condenser may the deethanizer. The ethane product recovered preferably
be connected to a condensed overhead outlet though which has a purity of at least about 70% , most preferably at least
at least a portion of the condensed overhead can be refluxed about 95 % .
back to the DWC and through which the remaining con- 65 In an alternative embodiment where the dividing wall
densed overhead comprising C2 hydrocarbons may be column serves as a deethanizer as well as a depropanizer and
removed as an ethane product. debutanizer, the hydrocarbon liquid feed fed into the DWC
 US 11,207,611 B1
5 6
contains C2 + hydrocarbons, and the process additionally present invention may be any liquid feed having one or more
includes recovering a second overhead comprising C2 hydrocarbon constituents to be separated from the liquid
hydrocarbons from the DWC as an ethane product. The step feed . The hydrocarbon liquid feed preferably includes one or
of recovering the second overhead as an ethane product may more C3 + hydrocarbons and may optionally also include C2
preferably using a refrigerant; optionally returning a portion ( ethane) and may include other trace constituents, including
include condensing the second overhead with a condenser , 5
but not limited to methane, water, sulfur, and carbon dioxide .
of the condensed overhead as reflux to the DWC ; and In the exemplary embodiments described herein , the hydro
removing the remaining condensed overhead as the ethane carbon liquid feed includes C3 (propane), C4 (butane) and
product. The ethane product preferably has a purity of at C5 + components . The hydrocarbon liquid feed anticipated
least about 70 % , most preferably at least about 95 % .
The process and system of the present invention is both 10 described
for use in the first and third exemplary embodiments
herein also additionally includes C2 ( ethane ). In
energy and cost - effective . The plot space needed for the certain exemplary
fractionation train is reduced as compared to prior art feed is a natural gasembodiments , the hydrocarbon liquid
systems using a larger number of distillation towers and /or well - heads (NGL ). Aliquid feed obtained from natural gas
NGL feed will typically have the
using externally heated reboilers on multiple columns for
providing the heat needed by the system for the fraction- 15 following composition ranges for C1 - C5 + hydrocarbons: C1
ation . The reduction in equipment needed may also result in (< 1.5 % liquid volume (LV ) of NGL feed ); C2 ( 10-60% LV
safety advantages due to the fact that fewer operators and of NGL feed ); C3 ( 40-65 % LV of all C3 + in NGL Feed );
maintenance personnel may be required. Moreover, the i -butane ( 5-20 % LV of all C3 + in NGL feed ); n -butane
reduction in the hydrocarbon inventory stored within the ( 10-40 % LV of all C3 + in NGL feed ); C5 + ( 10-35 % LV of
fractionation train at any given time could also enhance the 20 all C3 + in NGL feed ).
safety of the system . The heat energy input to the system is In each of the exemplary embodiments of the invention
primarily attributable to the externally heated reboiler of the described herein, a fractionation train consisting of two or
DWC , as opposed to less efficient systems using multiple more connected fractionation columns, including a dividing
externally heated reboilers. Given that all or a portion of the wall column (DWC ) and a deisobutanizer (DIB ) column, are
DWC may be operated at a pressure sufficient to allow 25 utilized to fractionate the hydrocarbon liquid feed . The
cooling air or water to be used to condense the C3 overhead , majority of all externally supplied heat energy supplied to
more expensive refrigerants are not required to produce the
propane product. In addition , given that the thermally the system is input to the system via the externally heated
reboiler of the DWC . The following definitions and descrip
coupled deethanizer and / or DWC operate at relatively low tions apply to each of the exemplary embodiments described
pressure such that refrigeration may be required to condense 30 herein , unless otherwise indicated .
the C2 overhead product, some embodiments of the inven As used herein , the term “ butane " can refer to both normal
tion are particularly well adapted for production of a fully
liquefied ethane product at low pressure for storage or butane ( n - butane) or n - C4 and isobutane ( i- butane) or i - C4 .
In the embodiments described herein , the C2 , C3 , n - C4 ,
export.
Additional aspects of the invention, together with the i - C4 , and C5 + hydrocarbon components of the hydrocarbon
advantages and novel features appurtenant thereto, will be 35 liquid feed are recovered as separate relatively pure prod
set forth in part in the description which follows, and in part ucts , however it should be understood that the invention can
will become apparent to those skilled in the art upon encompass the recovery of mixtures of these components.
examination of the following, or may be learned from the As used herein , the term " column ” refers to any system ,
practice of the invention. The objects and advantages of the device, or combination of systems and / or devices suitable
invention may be realized and attained by means of the 40 more for thecomponents
selective separation of a mixture
having differing containing
boiling points.twoSuchor
instrumentalities and combinations particularly pointed out
in the appended claims . columns can include, but are not limited to , scrub columns,
distillation columns , rectification columns, and stripping
BRIEF DESCRIPTION OF THE DRAWINGS columns as are known in the art. It should be understood that
45 the columns can include a shell or housing disposed at any
FIG . 1 depicts a process flow diagram of a system in angle, in any configuration, and / or having any length to
accordance with aa first embodiment of the present invention , diameter ( L/D ) ratio . For clarity and ease of description, the
wherein the system includes aa deethanizer thermally coupled columns will be further described in this detailed description
to a combined depropanizer and debutanizer dividing wall with reference to a vertical, cylindrical, column having a
column followed by a deisobutanizer integrated with a 50 L/D ratio of greater than 1 .
compressor. Each column can be empty, partially filled , or completely
FIG . 2 depicts a process flow diagram of a system in filled with one or more trays and / or packing materials to
accordance with aa second embodiment of the present inven- improve mass transfer and / or separation of the feed com
tion, wherein the system includes aa combined depropanizer ponents . The fill material and fill pattern in the columns may
and debutanizer dividing wall column followed by a 55 vary in the different columns. For example, the fill material
in one column can include one or more structured and / or
deisobutanizer integrated with a compressor.
FIG . 3 depicts a process flow diagram of a system in random packed materials while the fill material in another
accordance with a third embodiment of the present inven- column can include one or more trays. Also for example , the
tion, wherein the system includes a combined deethanizer, fill material in one fractionation zone of a dividing wall
depropanizer, and debutanizer double dividing wall column 60 column can include one or more structured and / or random
followed by a deisobutanizer integrated with a compressor. packed materials while the fill material in another fraction
ation zone of the dividing wall column can include one or
DETAILED DESCRIPTION OF EXEMPLARY more trays. Two or more types of fill material can be
EMBODIMENTS disposed in the fractionation columns. For example, a frac
65 tionation zone of a column can contain random dumped
The liquid feed containing hydrocarbons ( “ hydrocarbon packing beneath a feed introduction line or column inlet and
liquid feed ” ) that is fractionated in accordance with the one or more trays above the column inlet . One or more
 US 11,207,611 B1
7 8
chimney trays or other liquid trap - out device can be dis- described in U.S. Pat. Nos . 2,471,134 ; 5,755,933 ; 5,914 ,
posed in a fractionation zone of a fractionation column to 012 ; 6,347,533 ; 6,645,350 ; and 6,958,111 .
improve or aid in the withdrawal of a product. As used herein , the term “ externally supplied heat energy ”
As used herein , the term “ trays ” includes any type of tray refers to any heat energy source that is external to and not
or similar structure that improves the contact between gas 5 derived from components of the system , including without
and liquid phases within the column . Trays deemed accept- limitation components of the fractionation train, any hydro
able for purposes of the present invention include , but are carbon liquid feed fed to the fractionation train , or any
not limited to , perforated trays, sieve trays, bubble cap trays, components of any hydrocarbon liquid feed fed to the
floating valve trays, fixed valve trays, cross - flow trays, fractionation train . In other words , externally supplied heat
radial flow trays, multi - downcomer trays, dual flow trays, 10 energy does not arise from nor is it generated within the
baffle trays, snap - in valve trays, chimney trays, slit trays, system . For example, heat energy input to the system from
any high -capacity trays or any combination thereof. the compressor attached to the DIB does not qualify as
As used herein , the term “ packing material ” includes any " externally supplied heat energy ” because the heat energy is
type of structured and / or random shaped material disposed generated within the system (via compression of the DIB
within a column. The packing material can increase the 15 overhead ).
effective surface area within aa column, which can improve In all embodiments, the majority of all externally supplied
the mass transfer between liquid and gas phases within a heat energy supplied to the system is input to the system via
column. The packing material can be made of any suitable the externally heated reboiler of the DWC . Preferably, 95 %
material, for example metals , non -metals, polymers, ceram- or more of the total externally supplied heat energy to the
ics , glasses , or any combination thereof. Random packing 20 system for the primary purpose of driving fractionation of
material deemed acceptable for purposes of the present the hydrocarbons in the hydrocarbon liquid feed fed to the
invention can include , but is not limited to , Raschig rings , fractionation train is input to the system through the exter
Lessing rings , I -rings, NeXRing, saddle rings , Intalox nally heated reboiler of the DWC . As used herein , “ for the
saddles , Intalox Ultra, Tellerettes, Pall rings, U -rings , or any primary purpose of driving fractionation of the hydrocar
combination thereof. Structured packing deemed acceptable 25 bons in the hydrocarbon liquid feed ” means that the sole or
for purposes of the present invention can include, but is not principal function of the externally supplied heat energy
limited to corrugated sheets, crimped sheets , gauzes , grids, input to the system is for heating the hydrocarbon liquid feed
wire mesh , monolith honeycomb structures, or any combi- components in the to facilitate separation or fractionation of
nation thereof. Each column can be empty, partially filled , or the hydrocarbon components. It is understood that additional
completely filled with one or more trays and / or packing 30 sources of externally supplied heat energy could be supplied
materials to improve mass transfer and / or separation of the to the system for purposes other than fractionation of the
feed components. The fill material and fill pattern in the hydrocarbon liquid feed fed to the train . For example,
columns may vary in the different columns. For example, the externally supplied heat energy may be supplied the
fill material in one column can include one or more struc- system via mole sieve dryer regenerator heaters, amine
tured and / or random packed materials while the fill material 35 regenerator reboilers, or other equipment principally Incona
in another column can include one or more trays. Also for figured to supply heat energy for other processes .
example, the fill material in one fractionation zone of a preferred embodiment, 75 % or more of all externally sup
dividing wall column can include one or more structured plied heat energy supplied to the system for any purpose is
and / or random packed materials while the fill material in input to the system via the externally heated reboiler of the
another fractionation zone of the dividing wall column can 40 DWC .
include one or more trays. Two or more types of fill material In addition to the externally supplied heat energy, sources
can be disposed in the fractionation columns. For example, of internally supplied heat energy include compression of
a fractionation zone of a column can contain random the DIB overhead , any pumps used to transport the hydro
dumped packing beneath aa feed introduction line or column carbon liquid feed , and any sensible and / or latent heat
inlet and one or more trays above the column inlet . One or 45 attributable to one or more of the feed, product, column
more chimney trays or other liquid trap - out device can be liquid and vapor draws, reboiler, or condenser streams.
disposed in a fractionation zone of a fractionation column to The majority of all externally supplied heat is input to the
improve or aid in the withdrawal of a product. system at only one point — the externally heated reboiler of
Each column can be made of one or more metallic and / or the DWC . In all of the embodiments disclosed herein , the
non -metallic materials physically and chemically compat- 50 externally heated reboiler is configured to solely or princi
ible with the temperature, pressure , and contents of the pally function to provide externally supplied heat energy for
column . Suitable metallic materials for purposes of the purposes of driving fractionation of the hydrocarbons in the
present invention include, but are not limited to , ferrous hydrocarbon liquid feed . The external heat supply of the
alloys including carbon and stainless steels . externally heated reboiler directly supplies heat to the DWC
As used herein , the term “ dividing wall column ” refers to 55 and indirectly supplies heat to other portions and compo
any column having one or more dividing walls . As used nents of the system , including the deethanizer (when used)
herein , the term “ dividing wall” refers to a partition disposed and DIB . In a preferred embodiment, the externally heated
within an interior of a column to provide fractionation zones reboiler of the DWC is a furnace heated via combustion of
on either side of the dividing wall . Each dividing wall can externally supplied hydrocarbons and / or hydrogen. The
be either segmented or continuous. A dividing wall is 60 flames from the combustion directly heat the tubes in which
“ continuous ” if it extends between two points on the perim- the DWC bottoms circulate through the firebox of the
eter of a distillation column. Each dividing wall can be furnace. The external heat supply can alternatively be pro
parallel or non -parallel relative to a longitudinal axis of the vided via externally heated heat transfer fluids that pass
column. The fractionation zones can have the same or through the externally heated reboiler of the DWC for heat
different cross - sectional areas, volumes , or both . Each divid- 65 exchange with the bottoms of the DWC circulating through
ing wall can also be non - insulated , partially insulated , or the reboiler. The heat transfer fluids are heated externally to
completely insulated . Exemplary dividing wall columns are temperatures greater than the process and are heated through
 US 11,207,611 B1
9 10
interchange of hot gases and /or flames which are generated
through the combustion of hydrocarbons and / or hydrogen .
Exemplary heat transfer fluids include, but are not limited to ,
heavy hydrocarbons ( C10 + ) and /or inorganic liquids, engi-
neered heat transfer oils , steam and / or hot water.
As used herein , the term “ deisobutanizer column " or DIB
refers to any column utilized to separate i - butane from
n -butane .
Referring now to FIG . 1 , a fractionation train in accor-
dance with aa first embodiment of the invention is denoted by
reference numeral 10. Fractionation train 10 includes the
following distillation / fractionation columns: deethanizer
2202 , depropanizer /debutanizer dividing wall column
( DWC ) 2302 , and deisobutanizer ( DIB ) 2502. DWC 2302
includes a single dividing wall 16 which separates first
fractionation zone 18 from second fraction zone 20. Con-
denser 2203 is connected to deethanizer 2202. Condenser
2303 and externally heated reboiler 2305 are connected to
DWC 2302. Heat exchange reboiler 2505 and compressor
12 are connected to DIB 2502 .
In this embodiment, DWC 2302 preferably has a circular
cross - section and a single dividing wall 16 bisecting the
cross - section of the column to provide fractionation zone 18
and 20 on each side of dividing wall 16. The dividing wall
16 is continuous, may or may not be insulated , and does not
extend to the top and bottom of the DWC 2302. The length
of the column extending above the top of the dividing wall
16 is sufficient to install apparatus to create a top or
rectification section 32. The length of the column extending
below the bottom of dividing wall 16 is sufficient to install 30 When operated within that pressure range, air or water can
apparatus to create a bottom or stripping section 34. The
dividing wall 16 may have portions which run parallel and
perpendicular to the longitudinal axis of the column so as to
redistribute the cross - sectional area available for fraction-
ation zones 18 and 20 .
Fractionation train 10 can be utilized to fractionate a
hydrocarbon liquid feed that primarily includes C2 + hydro-
carbons as described herein . The hydrocarbon liquid feed
stream with C2 + hydrocarbons is fed via deethanizer inlet
2201 in the feed side 22 of deethanizer 2202 into fraction-
ation zone 24. Deethanizer 2202 is preferably operated at a
temperature ranging between -20 and 220 degrees Fahren-
heit and a pressure ranging between 135 and 350 psig . The
ethane within the hydrocarbon liquid feed is vaporized in
deethanizer 2202 , causing it to travel overhead to the top or
rectification section 26 and through overhead outlet 2206 as
an ethane overhead product. The ethane overhead product is
preferably in overhead outlet 2206 at a temperature ranging
from -20 to 100 degrees Fahrenheit and a pressure ranging
from 135 to 345 psig prior to entering condenser 2203. The
ethane overhead product is then condensed in condenser
2203 with a heat transfer medium or refrigerant that travels
through condenser 2203 via coolant inlet 2211 and coolant
outlet 2212. The ethane overhead product travels through
overhead outlet 2206 to one or more deethanizer reflux
drums 2204 , from which it can be removed . The ethane
overhead product in reflux drum 2204 is a relatively pure
product, preferably having an ethane content greater than
70 % , most preferably 95 % liquid volume (LV ). At least a
portion of the condensed ethane overhead product in reflux
drum 2204 can be refluxed back into the top or rectification
section 26 of deethanizer 2202 via reflux inlet 2207. The
remainder of the condensed ethane overhead product in
reflux drum 2204 may be removed as a relatively pure final
product of ethane via ethane outlet 2208 .
The liquid C3 + hydrocarbons of the hydrocarbon liquid
feed travel down and out of deethanizer 2202 through
bottom or stripping section 30 as a C3 + bottoms product via
DWC inlet 2301. At least a portion of the liquid C3 +
hydrocarbons are then fed through DWC inlet 2301 in the
feed side 64 where they enter a first fractionation zone 18 of
5 DWC 2302. DWC 2302 is preferably operated at a tempera
ture ranging between 75 and 400 degrees Fahrenheit and a
pressure ranging between 135 and 265 psig . All of the C3
hydrocarbons (propane ) and some of the C4 hydrocarbons
( n -butane and / or i -butane) in DWC 2302 travel up the first
10 fractionation zone 18 as vapor to top or rectification section
32. At least a portion of this vapor can be fed to bottom or
stripping section 30 of deethanizer 2202 via vapor outlet 36
in order to provide the column duty ( i.e. to heat the interior
of the deethanizer ) for the fractionation occurring within
15 deethanizer 2202. The column duty of deethanizer 2202 is
thus transferred from DWC 2302 such that deethanizer 2202
is “ thermally coupled ” to DWC 2302. With this arrange
ment, deethanizer 2202 does not require a separate reboiler
or other heat exchanger to heat deethanizer 2202. The
20 remainder of the C4 and all of the C5 + hydrocarbons travel
down DWC 2302 as liquid to bottom or stripping section 34
of DWC 2302 .
At the top or rectification section 32 of DWC 2302 , the
propane vapor is separated from any remaining C4 ( n -butane
25 and i -butane) and travels through overhead outlet 2306 as a
propane overhead product. The propane overhead product in
overhead outlet 2306 is preferably at a temperature ranging
from 75 to 125 degrees Fahrenheit and a pressure ranging
from 120 to 250 psig prior to entering condenser 2303 .
be used to serve as a heat transfer medium that condenses the
propane overhead product. The propane overhead product is
then condensed in condenser 2303 with air or water that
travels through condenser 2303 via coolant inlet 2311 and
35 coolant outlet 2312. Once the propane overhead product is
condensed in condenser 2203 , it travels to one or more DWC
reflux drums 2304 from which it can be removed . The
propane overhead product in DWC reflux drum 2304 is
relatively pure propane , preferably having a propane content
40 greater than 85 % , most preferably 95 % liquid volume (LV ).
At least a portion of the propane overhead product in DWC
reflux drum 2304 can be refluxed back to top or rectification
section 32 of DWC 2302 through reflux inlet 2307. The
remainder of the condensed propane in DWC reflux drum
45 2304 may be removed as a relatively pure final product of
propane via propane outlet 2308 .
The separation of C4 ( n -butane and i -butane) from C3
( propane) occurs in the upper portion of second fractionation
zone 20 of DWC 2302 , while the separation of C4 from C5 +
50 occurs in the lower section of second fractionation zone 20
of DWC 2302. A liquid DWC intermediate product that is
primarily C4 ( n -butane and i -butane) is drawn out of inter
mediate side 40 of DWC 2302 from second fractionation
zone 20 and is fed into DIB inlet 2501. The liquid C5 +
55 hydrocarbons are drawn off the bottom or stripping section
34 of DWC 2302 into C5 + outlet 2701 as a C5 + bottoms
product that is a relatively pure product, preferably having
a C5 + hydrocarbon content greater than 90% , most prefer
able 98 % liquid volume ( LV ). The liquid or bottoms in
60 bottom or stripping section 34 of DWC 2302 is heated with
an externally heated reboiler 2305 on the sump of DWC
2302. At least a portion of the liquid bottoms in bottom or
stripping section 34 of DWC 2302 , which is mostly C5 +
hydrocarbons, can be drawn into recycle inlet 2309 , heated
65 in externally heated reboiler 2305 , and fed back to bottom or
stripping section 34 of DWC 2302 through recycle outlet
2310. As discussed above, the externally heated reboiler
 US 11,207,611 B1
11 12
2305 can be a furnace that directly heats the bottoms More refrigeration is required to condense the ethane
circulating through the firebox of the furnace or a heat overhead product of deethanizer 2202 than is typically
exchanger with an externally heated heat transfer medium required in fractionation trains of the prior art due to the fact
exchanging heat with the bottoms liquid . The liquid in that deethanizer 2202 is thermally coupled with DWC 2302 ,
recycle outlet 2310 is preferably at a temperature ranging 5 which causes deethanizer 2202 to operate at a lower oper
from 250 to 400 degrees Fahrenheit and a pressure ranging ating pressure . However, this additional refrigeration cost is
compensated for by the decrease in overall heat input, lower
from 140 to 265 psig .
The DWC intermediate product in DIB inlet 2501 is fed of capital costs , and a reduced need for plot space . The scheme
to a fractionation zone 44 of DIB 2502 in order to separate 10 cooler fractionation train 10 , with a larger refrigeration duty and
2

i -butane from n - butane . DIB 2502 is preferably operated at cases where purity ethane product, may be more advantageous in
a temperature ranging between 70 and 150 degrees and a for storage ortheexport ethane is to be fully liquefied at low pressure
as the energy cost associated with the
pressure ranging between 35 and 90 psig . The i -butane is first phase of refrigeration will already have to be paid for.
vaporized within fractionation zone 44 of DIB 2502 , causing Alternatively, if a cooler ethane product is not desirable ,
itthrough
to traveloverhead
overhead to top or rectification section 46 and 15 once pumped , it could be integrated back into the process by
outlet 2506 as an i -butane overhead prod utilizing a side cooler in fractionation Zone 22 , or a cooling
uct . The i -butane overhead product in overhead outlet 2506 in the externally provided refrigeration loop .
is preferably at a temperature ranging from 70 to 120 Referring to FIG . 2 , a fractionation train in accordance
degrees Fahrenheit and a pressure ranging from 35 to 85 psig with aa second embodiment of the invention is denoted by the
prior to entering compressor 12. The i -butane overhead 20 numeral 110. Fractionation train 110 includes the following
product travels through overhead outlet 2506 and is com- distillation / fractionation columns : depropanizer /debutanizer
pressed via compressor 12 , thereby increasing the pressure dividing wall column ( DWC ) 3302 and deisobutanizer
2

such that it can transfer heat into the bottom of DIB 2502 (DIB ) 3502. DWC 3302 includes a single dividing wall 116
through heat exchanger reboiler 2505. The compressed which separates first fractionation zone 118 from second
i -butane overhead product is then fed through heat exchange 25 fractionation zone 120. Condenser 3303 and externally
reboiler 2505 via heat exchange reboiler inlet 56 and heat heated reboiler 3305 are connected to DWC 3302. Heat
exchange reboiler outlet 58. Simultaneously, at least a exchange reboiler 3505 and compressor 112 are connected
portion of the bottoms of DIB 2502 in bottom or stripping to DIB 3502 .
section 48 , which is mostly n - butane, is drawn into recycle
2 In this embodiment, DWC 3302 preferably has aa circular
inlet 2509 , heated in heat exchange reboiler 2505 through 30 cross - section and a single dividing wall 116 bisecting the
indirect contact with the compressed i -butane overhead cross - section of the column to provide fractionation zone
product, and fed back to bottom or stripping section 48 of 118 and 120 on each side of dividing wall 116. The dividing
DIB 2502 through recycle outlet 2510. The indirect contact wall 116 is co nuous, may or may not be insulated , and
of the i -butane overhead product with at least a portion of the does not extend to the top and bottom of the DWC 3302. The
bottoms of DIB 2502 in heat exchange reboiler 2505 pro- 35 length of the column extending above the top of the dividing
vides the heat exchange necessary to condense the com- wall 116 is sufficient to install apparatus to create a top or
pressed i -butane overhead product and vaporize the portion rectification section 132. The length of the column extending
of the liquid bottoms , which in turn provides the heat energy below the bottom of dividing wall 116 is sufficient to install
needed in DIB 2502 for fractionation . The bottoms in apparatus to create a bottom or stripping section 134. The
recycle outlet 2510 is preferably at a temperature ranging 40 dividing wall 116 may have portions which run parallel and
from 90 to 150 degrees Fahrenheit and a pressure ranging perpendicular to the longitudinal axis of the column so as to
from 40 to 90 psig . Once the i -butane overhead product is redistribute the cross sectional area available for fraction
condensed , it travels through heat exchange reboiler outlet ation zones 118 and 120 .
58 to one or more i -butane reflux drums 2504 , where it can Fractionation train 110 can be utilized to fractionate a
be removed . The i - butane overhead product in i - butane 45 hydrocarbon liquid feed that primarily includes C3 + hydro
reflux drum 2504 is relatively pure i -butane, preferably carbons ( little or no ethane is included ) as described herein .
having an i - butane content greater than 90 % , most prefer- Ethane could be removed from the hydrocarbon liquid feed
ably 96 % liquid volume ( LV ). At least a portion of the either off site or where fractionation train 110 is installed
condensed i -butane overhead product in i -butane reflux downstream of a conventional deethanizer. A hydrocarbon
drum 2504 can be refluxed back to the top or rectification 50 liquid feed stream with C3 + hydrocarbons is fed via DWC
section 46 of DIB 2502 through reflux inlet 2507. As shown , inlet 3301 in the feed side 164 to first fractionation zone 118
the portion refluxed back to DIB 2502 through reflux inlet of DWC 3302. DWC 3302 is preferably operated at a
2507 passes through an expansion valve 62 in order to adjust temperature ranging between 75 and 400 degrees Fahrenheit
for the pressure of DIB 2502. Cooling with air, water, or and a pressure ranging between 120 and 265 psig . All of the
refrigerant may occur on reflux inlet 2507 and / or i - butane 55 C3 (propane ) and some of the C4 ( n -butane and / or i -butane)
outlet 2508. In one exemplary embodiment, a cooler ( not in DWC 3302 travel up the first fractionation zone 118 as
shown ) can be connected to reflux inlet 2507 upstream from vapor to top or rectification section 132. The remainder of
expansion valve 62. The remainder of the condensed i-bu- the C4 and all of the C5 + hydrocarbons travel down the
tane overhead product in i - butane reflux drum 2504 may be column as liquid to bottom or stripping section 134 of DWC
removed as a relatively pure final product of i -butane via 60 3302 .
i -butane outlet 2508. The liquid n -butane travels down DIB At the top or rectification section 132 of DWC 3302 , the
2502 to the bottom or stripping section 48 of DIB 2502 and propane vapor is separated from any remaining C4 ( n -butane
is drawn off the bottom or stripping section 48 through and i -butane ) and travels through overhead outlet 3306 as a
n - butane outlet 2601 as an n -butane bottoms product that is propane overhead product. The propane overhead product in
a relatively pure final product of n - butane, preferably having 65 overhead outlet 3306 is preferably at a temperature ranging
a n -butane content greater than 90 % , most preferably 94 % from 75 to 125 degrees Fahrenheit and a pressure ranging
liquid volume (LV ). from 120 to 260 psig prior to entering condenser 3303 .
 US 11,207,611 B1
13 14
When operated within that pressure range , air or water can exchange reboiler 3505 through indirect contact with the
be used to serve as a heat transfer medium that condenses the compressed i -butane overhead product, and fed back to
propane overhead product. The propane overhead product is bottom or stripping section 148 of DIB 3502 through recycle
condensed in condenser 3303 with air or water that travels outlet 3510. The indirect contact of the i -butane overhead
through condenser 3303 via coolant inlet 3311 and coolant 5 product with at least a portion of the bottoms of DIB 3502
outlet 3312. Once the propane overhead product is con in heat exchange reboiler 3505 provides the heat exchange
densed in condenser 3303 , it travels to one or more DWC necessary to condense the compressed i -butane overhead
reflux drums 3304 from which it can be removed . The product and vaporize the portion of the liquid bottoms,
propane overhead product in DWC reflux drum 3304 is which in turn provides the heat energy needed in the DIB
relatively pure propane, preferably having a propane content 10 3502 for fractionation . The bottoms in recycle outlet 3510 is
greater than 85 % , most preferably 95 % liquid volume (LV ).
At least a portion of the propane overhead product in DWC preferably at a temperature ranging from 90 to 150 degrees
reflux drum 3304 can be refluxed back to top or rectification the i - butaneandoverhead
Fahrenheit a pressure ranging from 40 to 90 psig . Once
product is condensed , it travels
section 132 of DWC 3302 via reflux inlet 3307. The
through heat exchange reboiler
remainder of the condensed propane overhead product in 15 i -butane reflux drums 3504 , where outlet 158 to one or more
DWC reflux drum 3304 may be removed as a relatively pure it can be removed . The
final product of propane via propane outlet 3308 . i -butane overhead product in i -butane reflux drum 3504 is
The separation of C4 ( n -butane and i -butane) from C3 relatively pure i -butane , preferably having an i - butane con
( propane) occurs in the upper portion of second fractionation tent greater than 90 % , most preferably 96 % liquid volume
zone 120 of DWC 3302 , while the separation of C4 from 20 (LV ). At least a portion of the condensed i - butane overhead
C5 + occurs in the lower section of second fractionation zone product in i - butane reflux drum 3504 can be refluxed back
120 of DWC 3302. A liquid DWC intermediate product that to the top or rectification section 146 of DIB 3502 through
is primarily C4 ( n -butane and i -butane) is drawn out of reflux inlet 3507. As shown , the portion refluxed back to
intermediate side 140 of DWC 3302 from second fraction- DIB 3502 through reflux inlet 3507 passes through an
ation zone 120 and is fed through DIB inlet 3501. The liquid 25 expansion valve 162 in order to adjust for the pressure of
C5 + hydrocarbons are drawn off the bottom or stripping DIB 3502. Cooling with air, water, or refrigerant may occur
section 134 of DWC 3302 through C5 + outlet 3701 as a C5 + on reflux inlet 3507 and / or i -butane outlet 3508. In one
bottoms product that is a relatively pure product, preferably exemplary embodiment, a cooler (not shown ) can be con
having a C5 + hydrocarbon content greater than 90 % , most nected to reflux inlet 3507 upstream from expansion valve
preferably 98 % liquid volume ( LV ). The liquid or bottoms 30 162. The remainder of the condensed i -butane overhead
in the bottom or stripping section 134 of DWC 3302 is product in i -butane reflux drum 3504 may be removed as a
heated with an externally heated reboiler 3305 on the sump relatively pure final product of i - butane via i -butane outlet
of DWC 3302. At least a portion of the liquid bottoms in 3508. The liquid n -butane travels down DIB 3502 the
stripping section 134 of DWC 3302 , which is mostly C5 + bottom or stripping section 148 of DIB 3502 and is drawn
hydrocarbons, can be drawn into recycle outlet 3309 , heated 35 off the bottom or stripping section 148 through n -butane
in externally heated reboiler 3305 , and fed back to bottom or outlet 3601 as an n - butane bottoms product that is a rela
stripping section 134 of DWC 3302 through recycle inlet tively pure final product of n - butane, preferably having a
3310. As discussed above , the externally heated reboiler n - butane content greater than 90 % , most preferably 94 %
3305 can be a furnace that directly heats the bottoms liquid volume (LV ).
circulating through the firebox of the furnace or a heat 40 Referring to FIG . 3 , a fractionation train in accordance
exchanger with an externally heated heat transfer medium with a third embodiment of the present invention is denoted
exchanging heat with the bottoms liquid . The liquid in by numeral 210. Fractionation train 210 includes the fol
recycle outlet 3310 is preferably at a temperature ranging lowing distillation / fractionation columns: deethanizer /
from 250 to 400 degrees Fahrenheit and a pressure ranging depropanizer /debutanizer dividing wall column ( DWC )
from 125 to 265 psig . 45 4302 and deisobutanizer (DIB ) 4502. DWC 4302 includes
The DWC intermediate product in DIB inlet 3501 is fed two dividing walls 216 and 217 which form three fraction
to a fractionation zone 144 of DIB 3502 in order to separate ation zones within DWC 4302 : first fractionation zone 218 ,
i - butane from n - butane. DIB 3502 is preferably operated at second fractionation zone 219 , and third fractionation zone
a temperature ranging between 70 and 150 degrees Fahren- 220. Dividing wall 216 extends to the top of DWC 4302 ,
heit and a pressure ranging between 35 and 90 psig . The 50 thereby separating the top or rectification section 232 into a
i -butane is vaporized within fractionation zone 144 of DIB deethanizer zone 233 and a depropanizer zone 235 , which in
3502 , causing it to travel overhead to top or rectification turn allows for the production of separate overhead vapor
section 146 and through overhead outlet 3506 as an i - butane streams 4306 and 4322. Condensers 4303 and 4320 and
overhead product. The i -butane overhead product in over- externally heated reboiler 4305 are connected to DWC 4302 .
head outlet 3506 is preferably at a temperature ranging from 55 Heat exchange reboiler 4505 and compressor 212 are con
70 to 120 degrees Fahrenheit and a pressure ranging from 35 nected to DIB 4502 .
to 85 psig prior to entering compressor or compressor 112 . In this embodiment, DWC 4302 preferably has a circular
The i -butane overhead product travels through overhead cross - section and two dividing walls that provide cross
outlet 3506 and is compressed via compressor 112 , thereby sectional areas that correspond to the liquid and vapor loads
increasing the pressure such that it can transfer heat into the 60 within each of three fractionation zones 218 , 219 , and 220 .
bottom of DIB 3502 through heat exchange reboiler 3505 . Dividing walls 216 and 217 are continuous and may or may
The compressed i - butane overhead product is then fed not be insulated . Dividing wall 217 extends from above the
through heat exchange reboiler 3505 via heat exchange bottom of dividing wall 216 but not to the top of DWC 4302
reboiler inlet 156 and heat exchange reboiler outlet 158 . leaving room for depropanizer zone 235. Dividing wall 217
Simultaneously , at least a portion of the bottoms of DIB 65 extends down below the elevation of the bottom of 216 but
3502 in bottom or stripping section 148 , which is mostly not to the bottom of DWC 4302 leaving room for stripping
n -butane, is drawn into recycle inlet 3509 , heated in heat section 234 .
 US 11,207,611 B1
15
Fractionation train 210 can be utilized to fractionate a
hydrocarbon liquid feed that primarily includes C2 + hydro-
carbons as described herein . A hydrocarbon liquid feed
stream with C2 + hydrocarbons is fed via DWC inlet 4201 in
the feed side 264 of DWC 4302 to first fractionation zone
218 of DWC 4302. DWC 4302 is preferably operated at a
temperature ranging between –20 and 400 degrees Fahren-
heit and a pressure ranging between 120 and 350 psig . All
of the C2 ( ethane) within the hydrocarbon liquid feed is
vaporized in the first fractionation zone 218 causing it to
travel overhead to deethanizer rectification section 233 of
DWC 4302 and through overhead outlet 4322 as an ethane
overhead product. The ethane overhead product is then
condensed in condenser 4320 with a refrigerant that travels
through condenser 4320 via coolant inlet 4325 and coolant
outlet 4326. The ethane overhead product then travels
through overhead outlet 4322 to one or more ethane reflux
drums 4321 , where it may be removed. The ethane overhead
product in ethane reflux drum 4321 is relatively pure ethane ,
preferably having an ethane content greater than 70 % , most
preferably 95 % liquid volume (LV ). At least a portion of the
condensed ethane overhead product in ethane reflux drum
4321 can be refluxed back to the top or rectification section
232 in the fractionation zone 218 of DWC 4302 via reflux
inlet 4323. The remainder of the condensed ethane overhead
product in ethane reflux drum 4321 may be removed as a
relatively pure final product of ethane via ethane outlet 4324 .
The liquid C3 + hydrocarbons of the hydrocarbon liquid
feed travel down the first fractionation zone 218 and below
the first dividing wall 216. All of the C3 ( propane ) and some
of the C4 ( n -butane and / or i -butane) travel up the second
fractionation zone 219 as vapor to depropanizer zone 235 .
The remainder of the C4 and all of the C5 + hydrocarbons
travel down to the bottom or stripping section 234 of DWC
4302 as liquid . At the top of DWC 4302 in the portions of
the second and third fractionation zones 219 and 220 that are
located above second dividing wall 217 , the propane vapor
is separated from any remaining C4 ( n -butane and i -butane )
and travels up to depropanizer zone 235 and through over-
head outlet 4306 as a propane overhead product. The pro-
pane overhead product in overhead outlet 4306 is preferably
16
240 of DWC 4302 from third fractionation zone 220 and is
fed into DIB inlet 4501. The liquid C5 + hydrocarbons are
drawn off the bottom or stripping section 234 of DWC 4302
into C5 + outlet 4701 as a C5 + bottoms product that is a
5 relatively pure product, preferably having a C5 + hydrocar
bon content greater than greater than 90 % , most preferable
98 % liquid volume (LV ). The liquid or bottoms in the
bottom or stripping section 234 of DWC 4302 is heated with
a single externally heated reboiler 4305 on the sump of
10 DWC 4302. At least a portion of the liquid in bottom or
stripping section 234 of DWC 4302 , which is mostly C5 +
hydrocarbons, can be drawn into recycle inlet 4309 , heated
in externally heated reboiler 4305 , and fed back to bottom or
stripping section 234 of DWC 4302 through recycle outlet
15 4310. As discussed above, the externally heated reboiler
4305 can be a furnace that directly heats the bottoms
circulating through the firebox of the furnace or a heat
exchanger with an externally heated heat transfer medium
exchanging heat with the bottoms liquid . The liquid in
20 recycle outlet 4310 is preferably at a temperature ranging
from 250 to 400 degrees Fahrenheit and a pressure ranging
from 125 to 350 psig .
The DWC intermediate product in DIB inlet 4501 is fed
to a fractionation zone 244 of DIB 4502 in order to separate
25 i - butane from n- butane . DIB 4502 is preferably operated at
a temperature ranging between 70 and 150 degrees Fahren
heit and a pressure ranging between 35 and 90 psig . The
i -butane is vaporized within fractionation zone 244 of DIB
4502 , causing it to travel overhead to top or rectification
30 section 246 and through overhead outlet 4506 as an i -butane
overhead product. The i - butane overhead product in over
head outlet 4506 is preferably at a temperature ranging from
70 to 120 degrees Fahrenheit and a pressure ranging from 35
to 85 psig prior to entering compressor 212. The i -butane
35 overhead product travels through overhead outlet 4506 and
is compressed via compressor 212 , thereby increasing the
pressure such that it can transfer heat into the bottom of the
column through heat exchange reboiler 4505. The com
pressed i -butane overhead product is then fed through heat
40 exchange reboiler 4505 via heat exchange reboiler inlet 256
and heat exchange reboiler outlet 258. Simultaneously, at .

at a temperature ranging from 75 to 125 degrees Fahrenheit least a portion of the bottoms of DIB 4502 in bottom or
and a pressure ranging from 120 to 345 psig prior to entering stripping section 248 , which is mostly n -butane , is drawn
condenser 4303. When operated within that pressure range , into recycle inlet 4509 , heated in heat exchange reboiler
2

air or water can be used to serve as a heat transfer medium 45 4505 through indirect contact with the compressed i -butane
that condenses the propane overhead product. The propane overhead product, and fed back to bottom or stripping
overhead product vapor is then condensed in condenser section 248 of DIB 4502 through recycle outlet 4510. The
4303 with air or water that travels through condenser 4303 indirect contact of the i - butane overhead product with at
via coolant inlet 4311 and coolant outlet 4312. Once the least a portion of the bottoms of DIB 4502 in heat exchange
propane overhead product is condensed in condenser 4303 , 50 reboiler 4505 provides the heat exchange necessary to
it travels to one or more DWC reflux drums 4304 , where it condense the compressed i - butane overhead product and
can be removed . The propane overhead product in DWC vaporize the portion of the liquid bottoms, which in turn
reflux drum 4304 is relatively pure propane , preferably provides the heat energy needed in the DIB 4502 for
having a propane content greater than 85 % , most preferably fractionation . The bottoms in recycle outlet 4510 is prefer
95 % liquid volume ( LV ). At least a portion of the condensed 55 ably at a temperature ranging from 90 to 150 degrees
propane overhead product in DWC reflux drum 4304 can be Fahrenheit and a pressure ranging from 40 to 90 psig . Once
refluxed back to the top or rectification section 232 in the the i -butane overhead product is condensed, it travels
depropanizer zone 235 of DWC 4302 via reflux inlet 4307 . through heat exchange reboiler outlet 258 to one or more
The remainder of the condensed propane overhead product i -butane reflux drums 4504 , where it can be removed . The
in DWC reflux drum 4304 may be removed as a relatively 60 i - butane overhead product in i - butane reflux drum 4504 is
pure final product of propane via propane outlet 4308 . relatively pure i -butane, preferably having an i - butane con
The separation of C4 (n -butane and i -butane) from C3 tent greater than 90 % , most preferably 96 % liquid volume
( propane) occurs in the upper portion of third fractionation (LV ). At least a portion of the condensed i -butane overhead
zone 220 of DWC 4302 , while the separation of C4 from product in i - butane reflux drum 4504 can be refluxed back
C5 + occurs in the bottom or stripping section 234 of DWC 65 to top or rectification section 246 of DIB 4502 through reflux
4302. A liquid DWC intermediate product that is primarily inlet 4507. As shown, the portion refluxed back to DIB 3502
C4 ( n -butane and i-butane) is drawn out of intermediate side through reflux inlet 4507 passes through an expansion valve
 US 11,207,611 B1
17
262 in order to adjust for the pressure of DIB 4502. Cooling
with air, water, or refrigerant may occur on reflux inlet 4507
and / or i -butane outlet 4508. In one exemplary embodiment,
a cooler (not shown) can be connected to reflux inlet 4507
upstream from expansion valve 262. The remainder of the 5
condensed i - butane overhead product in i - butane reflux
drum 4504 may be removed as a relatively pure final product
of i -butane via i - butane outlet 4508. The liquid n - butane
travels down DIB 4502 to the bottom or stripping section
248 of DIB 4502 and is drawn off bottom section 248 10
through n -butane outlet 4601 as an n -butane bottoms prod
uct that is a relatively pure final product of n -butane,
preferably having a n -butane content greater than 90 % , most
preferably 94 % liquid volume ( LV ) .
More refrigeration is required to condense the ethane
overhead product of DWC 4302 than is typically required in
fractionation trains of the prior art due to the fact that the
separations of C2 , C3 , and C4 all occur within a single DWC
4302 as opposed to multiple distillation columns, which
causes first fractionation section 218 of DWC 4302 to
operate at a lower operating pressure . However, this addi-
tional refrigeration cost is compensated for by the decrease
in overall heat input, lower capital costs , and a reduced need
for plot space . The scheme of fractionation train 210 , with
a larger refrigeration duty and cooler purity ethane product,
may be more advantageous in cases where the ethane is to
be fully liquefied at low pressure for storage or export as the
energy cost associated with the first phase of refrigeration
will already have to be paid for. Alternatively, if aa cooler
ethane product is not desirable , once pumped, it could be
integrated back into the process by utilizing a side cooler in
fractionation zone 22 , or as cooling in the externally pro-
vided refrigeration loop .
It should be understood that although fractionation trains
10 , 110 , and 210 are each shown with only one condenser for
each individual overhead product stream and only one
reboiler for some of the distillation columns, it is within the
scope of the present invention to utilize two or more
condensers for a given overhead product stream or two or
more reboilers for a given distillation column . Furthermore, 40 comprises the step of:
the “ externally heated reboiler ” of the DWC is not limited to
a single reboiler apparatus and may include multiple exter-
nally heated reboiler components, provided all of the com-
ponents supply heated bottoms to the DWC .
From the foregoing it will be seen that this invention is 45 recovering a DIB overhead comprising isobutane from the
one well adapted to attain all ends and objectives herein
above set forth , together with the other advantages which are
obvious and which are inherent to the invention .
Since many possible embodiments may be made of the
invention without departing from the scope thereof, it is to 50 a DWC overhead comprising C3 hydrocarbons from the
be understood that all matters herein set forth or shown in dividing wall column as a propane product comprises con
the accompanying drawings are to be interpreted as illus- densing a DWC overhead comprising hydrocarbons with a
trative, and not in a limiting sense .
While specific embodiments have been shown and dis- thereof.
cussed , various modifications may of course be made, and 55 9. The process of claim 3 , wherein the process further
the invention is not limited to the specific forms or arrange-
ment of parts and steps described herein , except insofar as
such limitations are included in the following claims . Fur
ther, it will be understood that certain features and subcom-
binations are of utility and may be employed without 60
reference to other features and subcombinations. This is
contemplated by and is within the scope of the claims .
What is claimed and desired to be secured by Letters
Patent is as follows:
1. A process for fractionating a liquid feed comprising
hydrocarbons, the process comprising the steps of:
18
feeding a liquid feed to a dividing wall column wherein
the liquid feed comprises hydrocarbons selected from
the group consisting of C2 , C3 , C4, C5 + , and combi
nations thereof;
heating at least a portion of a DWC bottoms liquid of the
dividing wall column with an externally heated reboiler
to supply a majority of all externally supplied heat for
the process to the dividing wall column ;
feeding at least a portion of a DWC intermediate com
prising C4 hydrocarbons from the dividing wall col
umn into a deisobutanizer column;
compressing at least a portion of an overhead vapor of the
deisobutanizer column to form a compressed overhead
15 and circulating the compressed overhead through a heat
exchange reboiler to condense the compressed over
head ;
circulating at least a portion of a DIB bottoms liquid of the
deisobutanizer column through the heat exchange
20 reboiler to heat the DIB bottoms liquid and returning
the heated DIB bottoms liquid to the deisobutanizer
column; and
recovering one or more products from the dividing wall
column and / or the deisobutanizer column, wherein the
25 one or more products comprise relatively pure hydro
carbons and / or one or more combinations of hydrocar
bons .
2. The process of claim 1 , wherein the liquid feed com
prises a natural gas liquid feed .
30 3. The process of claim 1 , wherein the liquid feed com
2
prises C2 + hydrocarbons.
4. The process of claim 1 , wherein the liquid feed com
prises C3 + hydrocarbons.
5. The process of claim 1 , wherein the process further
35 comprises the step of:
recovering a DWC overhead comprising C3 hydrocar
bons from the dividing wall column as a propane
product.
6. The process of claim 1 , wherein the process further
recovering a DWC bottoms comprising C5 + hydrocar
bons from the dividing wall column .
7. The process of claim 1 , wherein the process further
comprises the step of:
deisobutanizer column as an isobutane product; and
recovering a DIB bottoms comprising n - butane from the
deisobutanizer column as an n - butane product.
8. The process of claim 5 , wherein the step of recovering
condenser using cooling water, air, and / or combinations
comprises the steps of:
feeding a liquid comprising C2 hydrocarbons to a
deethanizer column;
recovering a deethanizer overhead comprising C2 hydro
carbons from the deethanizer column as an ethane
product; and
feeding at least a portion of a? deethanizer bottoms to the
dividing wall column as the liquid feed .
10. The process of claim 9 , wherein the process further
65 comprises the step of:
feeding a portion of a vapor from the dividing wall
column to a bottom of the deethanizer.
 US 11,207,611 B1
19 20
11. The process of claim 10 , wherein the step of recov
ering a deethanizer overhead comprising C2 hydrocarbons
comprises condensing the deethanizer overhead with a con
denser using a refrigerant.
12. The process of claim 1 , wherein the process addition- 5
ally comprises the step of:
recovering a second DWC overhead comprising C2
hydrocarbons from the dividing wall column as an
ethane product.
13. The process of claim 12 , wherein the step of recov- 10
ering a second DWC overhead comprising C2 hydrocarbons
from the dividing wall column as an ethane product com
prises condensing the second DWC overhead comprising C2
hydrocarbons with a condenser using a refrigerant.
* * * * 15