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Process Safety and Environmental Protection 140 (2020) 86–99

Contents lists available at ScienceDirect

Process Safety and Environmental Protection


journal homepage: www.elsevier.com/locate/psep

Towards process, energy and safety based criteria for multi-objective


optimization of industrial acid gas removal process
Zainab Al Ani, Mohammed Thafseer, Ashish M. Gujarathi ∗ , G. Reza Vakili-Nezhaad ∗
Department of Petroleum & Chemical Engineering, College of Engineering, Sultan Qaboos University, P.O. Box 33, Al-Khod, P.C. 123, Muscat, Oman

a r t i c l e i n f o a b s t r a c t

Article history: Acid gas removal processes find significance in industries because of the need to meet government regu-
Received 6 February 2020 lations regarding the concentration of sweet gas. Also, the fact that the removed H2 S can be converted to
Received in revised form 18 March 2020 sulfur by the Claus process and the rising importance of carbon capture increases its importance. Opti-
Accepted 23 March 2020
mization of the process with regards to energy consumption and damage index is among the many cases
Available online 27 April 2020
carried out in this study using evolutionary algorithm, NSGA-II. The process is simulated using ProMax
4.0 which was linked to Excel to conduct the multi-objective optimization cases (EMOO). Hydrocarbon
Keywords:
recovery and sulfur removal have also been optimized. Detailed analysis of the two-objective optimiza-
Acid gas removal
DEPG
tion cases is carried out in the study followed by a three-objective case which is then compared with the
Multi-objective optimization two-objective cases and the results are reported. With industries operating under more than two objec-
Energy considerations tives, the three-objective case would provide more practical results. A four-objective case optimization
Hydrocarbon recovery study, which combines all the studied objectives, is also carried out for more industrial practical solu-
Safety indices tions. The decision makers will be able to analyze the Pareto-optimal solutions to determine the preferred
operating point.
© 2020 Institution of Chemical Engineers. Published by Elsevier B.V. All rights reserved.

1. Introduction The solvent used in this study is Dimethyl Ether of Polyethylene


Glycol (DEPG), a constituent of Selexol® , and has a generic formula
Syngas produced from gasification processes contain gases like CH3 (CH2 CH2 O)n CH3 , where n is between 3 and 9. Its non-reactive
H2 S and CO2 , which being acidic in nature can cause significant nature and thermal stability gives it the edge over methanol. In
harm to process equipment and work staff. These effects are mag- addition, owing to the high vapour pressure of methanol, refriger-
nified at extreme process conditions which can lead to corrosion ation costs are very high while DEPG does not require a water wash
of pipelines and casings. Government regulations have been set up to recover the solvent (Burr and Lyddon, 2008). The solubility of CO2
to control the concentration of these gases, especially H2 S which is and H2 S in DEPG is higher than that of CH4 and the former gases
poisonous, in the released streams (George et al., 2016; Kohl and will be preferred over the latter. Also, among these gases, DEPG has
Nielsen, 1997). Acid gas removal, as a result, becomes a necessary a high selectivity of H2 S over CO2 (Dyment and Watanasiri, 2015;
step in these industries. Current processes that remove acid gases Nassar et al., 2000).
use different kinds of solvents and the most common ones are either The first case of optimizing a process would have been when
chemical solvents or physical solvents (Astaria et al., 1983). The dif- conditions were tweaked to improve the profits generated before
ference between the two is that the former removes the gases from the era of computing and mathematical algorithms. As time passed,
the feed stream by chemical reaction while the absorption leads to engineers began searching for methods to decrease energy con-
removal using the latter. The presence of high concentration of acid sumption and improve gas recovery. This led to the development
gases in the feed stream, like in this study, gives physical solvents of modeling and simulation of processes and along with that, the
the nod ahead of chemical solvents. Also, solvent regeneration is need for optimization techniques arose. Single objective optimiza-
achieved by pressure reduction or the application of heat (Dyment tion did not give the users much scope for improvement and as a
and Watanasiri, 2015). result, there have been advancements in the field of multi-objective
optimization (MOO), where more than one objective is considered
for optimization (Deb, 2014; Gong et al., 2014, 2013; Liu et al.,
2017). Evolutionary Algorithms, especially ones that converge to
∗ Corresponding authors. global solutions rather than just the local front, have been preferred
E-mail addresses: ashishg@squ.edu.om, ashishgujrathi@gmail.com in recent times because of their ability to solve real world problem
(A.M. Gujarathi), vakili@squ.edu.om (G.R. Vakili-Nezhaad).

https://doi.org/10.1016/j.psep.2020.03.023
0957-5820/© 2020 Institution of Chemical Engineers. Published by Elsevier B.V. All rights reserved.
Z. Al Ani et al. / Process Safety and Environmental Protection 140 (2020) 86–99 87

with ease (Adeyemo and Stretch, 2018; Dulebenets, 2019; Gong gas streams. Processes using a solvent for the removal are more
et al., 2018a,b; Maier et al., 2019; Monsef et al., 2019). common, especially while dealing with syngas and natural gas
Carbon capture has been proposed as a mean to minimize CO2 (Korens et al., 2002). Being the cheaper alternative, amine-based
being emitted into the atmosphere (Bosoaga et al., 2009). This helps chemical solvents are generally preferred. However, the presence
especially in the case of Integrated Gasification Combined Cycle of high amounts of acid gases in the stream means physical solvents
(IGCC) plants that produce a lot of CO2 , which needs to be dis- are required. Selexol® solvent, or DEPG, is selected over methanol
posed, within the environmental regulations, in place (Kawabata because of its ability to operate at normal temperatures and low
et al., 2013). IGCC plants have an acid gas removal unit to purify toxicity.
the syngas, with the exit stream being sent to the Claus process to The acid gas removal process using DEPG has been depicted
produce sulfur. Instead of releasing the CO2 to the open, it is cap- in Fig. 1. The feed, dry basis sour gas, is a gas mixture containing
tured and sent to sequestration sites (Palmer, 2012). The Selexol® 81.98 % CH4 , 18 % CO2 and 128 ppm H2 S by mole basis. After being
process, which uses the DEPG solvent, is utilized in the acid gas saturated with steam, this stream now called sour feed, enters a
removal unit to remove H2 S and CO2 from the syngas (Gatti et al., 10-stage high pressure absorber where it comes in contact with
2015; Im et al., 2015; Yavini et al., 2015). Stephens (2005) stud- two DEPG streams of different concentrations. The lean solvent
ied different sequences for the removal of H2 S and CO2 . One was enters the top stage of the absorber from the bottom of the stripper
to separate each gas individually by keeping the H2 S removal sys- after passing through the refrigeration unit, while the semi lean
tem first. Another choice is to erect a unit that absorbs both the solvent is the bottom of the low pressure flash tank (LP Flash).
gases. The second option was considered in this study (Stephens, Concentrated solvent, termed as Rich DEPG, is flashed under high
2005). A dual-stage Selexol® process was simulated by Kapetaki pressure in another tank (HP Flash) and the top product returns
et al. (2015) to find operating conditions required to reach specific to the absorber after being cooled. The sulfur free gas leaves from
goals in regards to recovery of acid gases (Kapetaki et al., 2015). the top of the absorber after the acid gases have been absorbed
MOO was used to solve single bed adiabatic operation and steam by the solvent streams. The rich solvent exits from the bottom of
injection pseudo isothermal operation of styrene reactor, where the absorber to the HP Flash. As said before, the vapour stream
multi-objective differential evolution (MODE) algorithm results of the HP Flash is compressed, cooled and then sent back to the
were compared to NSGA algorithm (Gujarathi and Babu, 2009). absorber. The liquid stream goes to the heat recovery system and
An improved version of NSGA-II that includes the use of jump- then a preheater to raise its temperature before entering the LP
ing gene was used to solve three problems of an industrial semi Flash. Vapour stream from the LP Flash is the CO2 rich gas, which
batch nylon-6 reactor (Ramteke and Gupta, 2008). The maximiza- can be sent to a Claus process to convert the H2 S to sulfur and then
tion of high-value end products and minimization of low-value end for carbon capture. The energy in the vapour stream can also be
products were among the objectives considered for the MOO of used to produce electricity instead of wastage. The bottom stream
petroleum processing units using NSGA-II (Ivanov and Ray, 2014). from the LP Flash forms the semi lean solvent stream after pass-
Ochieng et al. (2013) discussed the minimization of total energy ing through the makeup tank and is cooled by the heat recovery
and maximization of hydrocarbon recovery in the Benfield HiPure system and a cooler before entering the absorber. A portion of
Gas Sweetening Unit. These objectives are among the ones that this stream is split and sent to the 5-stage low pressure strip-
will be evaluated in this study (Ochieng et al., 2013). The cumene per after heating. This stream is stripped in the presence of air
production process was optimized for several objectives, which and the top stream consisting mainly of the acid gases is released.
included a safety-based one and the optimization was carried out The bottom stream containing traces of the gases is now the lean
with NSGA-II with EMOO means (excel-based MOO). The study solvent, which after refrigeration enters the absorber. The SRK
was able to achieve critical findings regarding cumene process Polar property package was used in the simulation using ProMax
improvement (Sharma et al., 2013). The production of levulinic acid 4.0.
from empty fruit bunch was optimized for safety, environment and Validation of the process was carried out by comparing the
economic objectives using genetic algorithm. The obtained Pareto- results of this process with that of Doctor et al. (1993). The feed
fronts showed a good potential for improving the process (Hafyan for both the processes is a mixture of about 40 % nitrogen, 30 %
et al., 2020). hydrogen, 25 % CO2 , and trace amounts of CO, water, methane and
The objectives in this study are optimized using NSGA-II (Deb, H2 S. Doctor et al. (1993) had carried out the process at high and
2002). The Pareto-optimal front obtained is analyzed by the deci- low pressure. Since this study focuses on a high pressure process,
sion makers in order to find the best operating point for the only that is compared.
industry. The considered objectives are increasing the recovery of The AGR process has a better composition for the sweet gas,
CH4 and H2 S removal and to minimize the total consumed heat which is due to the presence of a semi lean solvent stream which
and damage index (DI). These four objectives are combined to form is absent in the IGCC process. The composition of the rich solvent
four cases with bi-objective nature and one case with three and leaving the absorber was also checked and it has higher concen-
four objectives. This is the first time for a research work to optimize tration of acid gases than the IGCC counterpart does. Thus it can
these objective combinations and cases. For this purpose, several be concluded that the simulation compares reasonably and gives
decision variables and limitations are taken into consideration. A improved results (see Table 1).
visual basic application (VBA) code is used to act as an interface
between ProMax v4.0 simulator and the Excel-based MOO, NSGA-
II. The user provides the ranges of the decision variables and the
required constraints for the optimization. The VBA code accesses 3. Problem formulation
the variables from the simulator at every stage of the optimization
run, which is then stored in Excel and can be utilized by the user In an era where energy demand has been sky rocketing, the
for calculations and analysis. amount of heat consumed by an industrial process comes into
focus. Sweetening processes require large amounts of energy to
2. Process description reach the required purity for the sweet gas. With the rising energy
costs, it becomes necessary to include minimization of the Total
There are a number of acid gas removal (AGR) processes run- Heat of the process among the considered objectives for multi-
ning in industries all over the world treating a wide variety of objective optimization. The total heat of the system is found by
88 Z. Al Ani et al. / Process Safety and Environmental Protection 140 (2020) 86–99

Fig. 1. Acid Gas Removal using DEPG (ProMaxv4.0, 2018).

Table 1
Comparison of IGCC and AGR processes.a .

Component Sour Feed lbmol/h Treated Gas lbmol/h Rich Solvent lbmol/h CO2 Rich Gas lbmol/h

IGCC AGR IGCC AGR IGCC AGR

CO2 4336 216.93 199.41 4234.74 4685.3 4119.06 4107.8


H2 S 0.4 0.04 0.00137 0.4 0.75794 0.36 0.37731
a
IGCC - Doctor et al. (1993) study results, AGR - Present study results.

calculating the difference between energy utilized and energy hazards and allows engineers to foresee possible effects of process
released. conditions. Although I2SI includes DI, Process and Hazard Con-
 trol Index (PHCI) and Inherent Safety Index (ISI), calculation of ISI
Total heat = (Qpumps + Qrecompressor + Qheaters − Qcoolers ) (1)
involves giving values to guidewords based on applicability and
where Q is the total energy consumed in the utility units (pumps, PHCI requires ranking of parameters which is subjective to indi-
compressors, heaters and coolers) in kJ/h. vidual safety experts (Khan and Abbasi, 2001; Sharma et al., 2013).
Maximization of sulfur removal is important for the process Hence, only DI is considered in this study and since, I2SI is inversely
to keep the sweet gas concentration within the limits set by proportional to DI, to maximize I2SI, DI is minimized in the simu-
the regulations. Considering that the solvent has some affinity to lation. Sharma et al. (2013) provides a detailed calculation of DI
hydrocarbons, CH4 recovery needs to be maximized to make sure that includes Fire and Explosion Damage Index (FEDI) and Toxicity
large amounts of the CH4 does not leave with the solvent. Enhanc- Damage Index (TDI).
ing the ability of the solvent by changing process conditions will
improve sulfur removal but will also result in more CH4 leaving 3.1. Decision variables and constraints
with the solvent.
H2 S in sour gas − H2 S in sweet gas ProMax was used to run a sensitivity analysis in order to find
% H2 S Removal = ∗ 100 (2) the decision variables affecting this process. The analysis con-
H2 S in sour gas
cluded that the temperature, pressure and vapour volumetric flow
CH4 in sweet gas
% CH4 Recovery = ∗ 100 (3) rate of the feed gas, Sour Feed, (Tsourgas, Psourgas and Fsourgas
CH4 in sour gas respectively) along with the temperature of the lean solvent, Tlean-
where H2 S in sour gas and CH4 in sour gas are the content of H2 S and DEPG, and the semi lean solvent, TsemileanDEPG affected the outlet
CH4 in the feed (Sour Feed), H2 S in sweet gas and CH4 in sweet gas are stream concentrations. The objectives, decision variables and con-
H2 S and CH4 content in the Sulfur Free Gas stream. straints of the acid gas removal process have been tabulated and
Gas processes dealing with high flow rates, temperatures and displayed in Table 2. Constraint of the H2 S fraction is set at 4 ppm
pressures tend to be very accident prone. In cases like these, it is to meet government standards.
important to have a mathematical formula to measure the degree Four two-objective cases, one three-objective case and a four-
of damage that such accidents can cause. One such tool is the objective case have been identified and the optimization has been
Integrated Inherent Safety Index (I2SI) which considers potential carried out. The cases are:
Z. Al Ani et al. / Process Safety and Environmental Protection 140 (2020) 86–99 89

Table 2
Objectives, decision variables and constraints values used in present study

Objective Decision variables Constraints

275 K < Tsourgas < 303 K


Maximize %H2 S Removal 4300 kPa < Psourgas <10040 kPa H2 S fraction in sulfur free gas <4 ppm
Maximize %CH4 Recovery 2.12 MSm3 /day < Fsourgas < 5.39
CO2 fraction in CO2 rich gas >60%
Minimize Total Heat MSm3 /day
Minimize DI 277 K < TleanDEPG < 311 K End Approach Temperature > 3 K
277 K < TsemileanDEPG < 311 K

• Case 1: Maximization of %H2 S Removal and minimization of Total in the Total Heat involved in the process. With 4 ppm being max-
heat imum tolerable concentration of H2 S in the sweet gas, a removal
• Case 2: Maximization of %H2 S Removal and minimization of DI rate of 97.5 % is accepted. If energy recovery is highly desired, the
• Case 3: Minimization of Total Heat and DI plot can be used by the design engineer to decide on the operating
• Case 4: Maximization of %CH4 Recovery and minimization of DI point for the industry.
• Case 5: Maximization of %H2 S Removal, and minimization of Total
Heat and DI • Case 2: %H2 S Removal vsDI
• Case 6: Maximization of %H2 S Removal and %CH4 Recovery and
minimization of Total Heat and DI Industrial processes require various indices to measure the con-
sequences of accidents at the plant. Couple of these, namely FEDI
NSGA-II has been used to run the cases with a population size of and TDI are measured and combined to form DI. DI gives an idea of
150 individuals and for 200 generations. The crossover and muta- how safe a process is at the given conditions. Here the goal is to find
tion probabilities used are 0.9 and 0.02 respectively. The obtained solutions for the case involving the maximization of H2 S removal
Pareto-optimal fronts and the effect of decision variables are dis- while minimizing DI to make sure the process is as safe as possible.
cussed in the next section. Fig. 3a gives the Pareto optimal solutions for the given case and
a trade-off can be seen emerging. Major conditions which affect
4. Results and discussion DI are sour gas flow rate and pressure. High flow rates and pres-
sures, along with high temperatures generally make the process
4.1. Two-objective optimization study more accident prone and can cause heavier damages. High sour gas
temperature of 303 K is seen is majority of the solutions (Fig. 3(b
• Case 1: %H2 S Removal vs Total Heat and c)), but pressure and flow rate dominates DI and as a result no
defined pattern is observed. After 99.5 % H2 S removal rate, the tem-
In an age where energy demands are rising, it becomes impor- perature falls to aid further absorption by the solvent and removal
tant to make sure wastage is as low as possible. The goal in this rate approaches a maximum of 99.95 %. As in the case analyzed
case is to maximize H2 S removal keeping the energy utilized in the before, lean solvent temperature has been fixed by the algorithm
process minimum and the results are plotted in Fig. 2a. The effect of at 277 K so as to have DEPG at maximum capacity (Fig. 3(h and
the different decision variables on the objectives has been shown i)). Feed gas pressure and flow rate, and semi lean solvent temper-
in Fig. 2(b–k). ature, have a combined effect and this will be explained as such
At first glance, the Pareto-optimal front in Fig. 2a gives a straight- (Fig. 3(d–g, j and k)). Up to H2 S removal of 99 %, the feed flow
forward trend. The total process heat involved is seen to increase rate and pressure remain constant at 2.94 MSm3 /day and 4300 kPa
on improving the sweet gas by removing more H2 S. In order to respectively. Semi lean solvent temperature is around 302.59 K and
decrease the concentration of H2 S in the sweet gas, the process a steady rise in H2 S removal is noted. This occurs due to an increase
needs more DEPG and also higher operating pressure. In the case in solvent flow rate. Since the solvent is liquid, it does not affect DI
of the sour gas temperature, simulation keeps it high, at 303 K, much and only a slight increase from 403 to 415 is observed in
till it approaches 100 % as seen in Fig. 2b. Higher temperatures that range. On passing the sharp change in the plot of Fig. 3a, feed
help in more energy release at coolers and a drop in temperature gas pressure and flow rate increases sharply to 9000 kPa and 3.35
after -1.5 × 106 kJ/h leads to a fall in the Total Heat in the pro- MSm3 /day respectively, and semi lean solvent temperature drops
cess (Fig. 2c). Solvent and semi lean solvent temperatures are fixed to 277 K. This improves H2 S removal beyond 99 % due to better
at the minimum of 277 K to enhance the absorption capability of absorption owing to the pressure and solvent temperature. Also, a
DEPG. This improves H2 S removal but does not help with the pro- sudden increase in DI, from 415 to 515 within 0.5 % of H2 S removal,
cess heat as less energy released at the exchangers (Fig. 2(h, I, j and is observed. This is unsurprising since the calculation of DI deriva-
k)). The major effect on the objective is caused by the pressure and tives like FEDI and TDI is affected directly by the physical state of
flow rate of the feed. From Fig. 2(d and f), it can be observed that the stream, its operating pressure and flow rate.
increasing the pressure to 7600 kPa while keeping flow rate high Although very pure sweet gas is preferable, it is not logical or
at 5.38 MSm3 /day leads to the H2 S removal reaching 99.5 %. This economical to reach that level of purity. Another factor that limits
occurs because pressure aids absorption and as a result, higher H2 S the purity is the damage index. As seen from the right hand por-
removal rates are achieved with rise in pressure. When the pressure tion of the plot in Fig. 3a, a 0.2 % increase from 99.7 % H2 S removal
becomes constant at 7600 kPa, further increase in H2 S removal is increases the DI by 25 %. Such a high value of DI should be discour-
because of the decrease in the feed flow rate, which makes it easier aged since very high flow rate of gases at high pressure could cause
for the solvent to absorb the acid gases. The effect of similar changes serious damage to industrial property and the workforce.
in process conditions on Total Heat is observed in Fig. 2(e and g).
The increase in pressure of the gas at constant flow rate adds to the • Case 3: Total Heat vsDI
duty on the pumps which in turn increases the energy required.
Lowering the inlet flowrate as pressure becomes constant means In industry, the safest processes are the ones which have less
energy in the streams also drops, as a result of which energy is release of heat and this is corroborated in the Fig. 4a. In this case,
released in the coolers and refrigeration falls. This leads to increase the objective was to minimize the Total Heat involved in the pro-
90 Z. Al Ani et al. / Process Safety and Environmental Protection 140 (2020) 86–99

Fig. 2. Case 1, maximization of %H2 S Removal and minimization of Total Heat of the process (a) The Pareto set at generation 200 for the process. (b–k) comparison of values
of decision variables for the process corresponding to the points on Pareto set in Fig. 2a.
Z. Al Ani et al. / Process Safety and Environmental Protection 140 (2020) 86–99 91

Fig. 3. Case 2, maximization of H2 S removal and minimization of DI (a) The Pareto set at generation 200 for the process. (b–k) comparison of values of decision variables for
the process corresponding to the points on Pareto set in Fig. 3a.
92 Z. Al Ani et al. / Process Safety and Environmental Protection 140 (2020) 86–99

Fig. 4. Case 3, minimization of Total Heat and DI (a) The Pareto set at generation 200 for the process. (b–k) comparison of values of decision variables for the process
corresponding to the points on Pareto set in Fig. 4a.
Z. Al Ani et al. / Process Safety and Environmental Protection 140 (2020) 86–99 93

cess and the DI simultaneously. Fig. 4a shows the Pareto-optimal DI to very high values (nearly 500) as large amounts of vapour and
front for this problem while Fig. 4(b–k) has the dependence of these gas is present in the system, due to the large flow rate, at high pres-
objectives on the different decision variables affecting the outcome sure. These conditions are dangerous to operate at and care must
of the process. be taken. The effect of pressure on DI is way more than on methane
Closer inspection of Fig. 4a reveals that higher DI values at recovery, hence the steep increase in slope after DI value of 420
obtained when more energy is released and here is the expected in Fig. 5a. The effect of the semi lean solvent is interesting to note
trade-off. Since the aim is to have a process as safe as possible, (Fig. 5(j and k)). Initially, CH4 recovery increases despite the tem-
there arises a need to sacrifice on the amount of heat. Simulation perature falling to 277 K due to the high flow rates. Then the rising
has fixed the feed gas temperature to 303 K (Fig. 4(b and c)). Sour temperatures decrease the solvent’s absorption and hence recov-
gas pressure is set at 4300 kPa since high pressures increase the ery increases further. Decreasing the temperature increases DI as
duty on pumps and increase heat requirements as well as mak- the lower temperatures improves the absorption leading to more
ing the process more dangerous, increasing DI (Fig. 4(d and e)). As gases in the exit streams after flashing. Then as the solvent tem-
seen in Fig. 4(h and i), TleanDEPG is fixed at the lowest tempera- perature increases, DI increases as higher temperatures make the
ture of 277 K to maximize absorption. The sour gas flow rate has process susceptible to fires.
the biggest effect on both the objectives. Increasing the flow rate Table 3 shows the values of the objectives and their respective
from 3.05 MSm3 /day to 5.38 MSm3 /day, while increasing DI in the decision variables for the selected points. Note that A and E are the
process (Fig. 4g), reduces heat requirements as seen in Fig. 4f. More points with the lowest and highest value of %CH4 Recovery and DI.
flow rate can be equated as more energy in the system and since Point A has a recovery rate of 93.22 % and a DI value of 404.82 while
the feed is at higher temperatures, more energy will be released E has CH4 recovery of 96.30 % and its damage index is 497.03. All
at the coolers and the refrigeration unit. DI calculations give the other points will fall between these two extremes. For example,
highest weightage to flow rates and very high values lead to high point B’s values are 94.92 % and 411.53 which can also be observed
DI. This can also be inferred logically as higher flow rates would from the trend in Fig. 5a. Point C shows the point where the increase
make it harder to control the fluids and hence, more susceptible to in DI shifts from gradual to steep. This can be seen in the table
damages, like fires or toxic spread of gases. Low flow rates and high by observing pressure and flow rate of the feed for points D and
semi lean solvent temperatures at the same time, reduces the heat E. The reason for the increase in pressure and flow rate beyond
released at coolers and this leads to higher Total Heat in the pro- C was explained in the previous paragraph. A desired increase in
cess (Fig. 4j). On the other hand, decreasing TsemileanDEPG from hydrocarbon recovery would automatically lead to an increase in
294 K to 277 K will improve the ability of the solvent to absorb the DI as observed while moving from point A to point E. A recovery
gases and this will lead to higher DI as more gases will be in the rate of about 96 % should be acceptable as further increase would
exit streams after being flashed (Fig. 4k). As is always the case, the lead to massive hike in the DI but the final decision lies with the
operating point of the plant has to be decided depending on which process engineer.
objective matters more for the process.
4.2. Three-objective and four-objective optimization study
• Case 4: %CH4 Recovery vsDI
• Case 5: Total Heat vs %H2 S Removal vs DI
In a process where the primary objective is to remove sulfide, • Case 6:Total Heat vs %H2 S Removal vs DIvs %CH4 Recovery
methane recovery is also considered to make sure large amounts of
methane do not leave with the waste gas streams. DI is an objective Industries rarely operate with just two objectives. Most of the
in this case so that the process is within limits and will not cause time, the there are multiple objectives that need to be optimized
extensive harm to equipment or personnel. Case 4 examines the simultaneously. The 3 different objectives considered in the earlier
trade-off when %CH4 Recovery is maximized and DI is minimized cases, viz. %H2 S Removal, Total Heat and DI, were pitted against
at the same time. The optimum solutions of the optimization are each other and the result is the Fig. 6a. The objectives in this case
seen in Fig. 5a while Fig. 5(b–k) have the individual dependence of were to maximize the %H2 S Removal while minimizing process
the objectives on the decision variables. heat and DI at the same time. Fig. 6b represents the four-objective
Initial analysis of Fig. 5a shows that increasing the %CH4 Recov- case, where %CH4 Recovery maximization objective is added to the
ery leads to higher DI values which is gradual at first and then three-objective case. Longer convergence times can be expected in
rises sharply after 96 %. Very low temperatures lead to the sol- three-objective and four objective optimizing cases mainly because
vent absorption at very high capacity and a possibility of methane of the influence of the third and fourth objective addition.
being absorbed as well. Sour feed is kept constant at 303 K to avoid The following figures and tables compare this three- and
the same (Fig. 5(b and c)). However, lean solvent temperatures are four-objective case with each of the two-objective cases. The
kept at 277 K, as seen in Fig. 5(h and i) to aid the absorption and Pareto-optimal fronts of the figures that follow show that the indi-
also make sure DI isn’t very high. The effect of pressure and flow vidual two-objective cases are basically the best solutions of the
rate of the sour feed on the objectives can be explained together. three-objective case. In each figure, the two-objective front lies on
Observing Fig. 5(d and f), %CH4 Recovery is directly influenced by the periphery of the three-objective plot when considering the two
feed flow rate. As the flow rate increases from 3.26 MSm3 /day to objectives alone. The presence of the third objective gives solutions
5.38 MSm3 /day, the recovery proportionally climbs from 93 % to which are further away from this periphery, which is the same case
96 %, while the pressure is constant at 4300 kPa. High flow rates for the fourth objective.
at low pressures, makes sure that the amount of methane that is The results of the two-objective (Case 1, maximization of %H2 S
absorbed by the solvent is not every high and this improves the Removal and minimization of Total Heat), three-objective (Case 5,
recovery. At constant flow of 5.38 MSm3 /day, a large increase in maximization of %H2 S Removal, and minimization of Total Heat
pressure is required to raise the recovery from 96 % to 96.5 %. Sim- and DI) and four-objective (Case 6, maximization of %H2 S Removal
ilarly, for DI, Fig. 5(e and g) shows the increase in DI to 420 as and %CH4 Recovery, and minimization of Total Heat and DI) opti-
the flow rate increases at constant pressure. A sudden rise is seen mization comparison studies have been represented in Fig. 7. The
because DI depends a lot on the flow rates involved in the process difference between both the cases has been analyzed and the
and all flow rates depend on the feed flow rate. When flow rate results for a few distinct %H2 S Removal values have been compiled
reaches maximum, the consequent increase in pressure increases in Table 4. As is observed in the table, the points being compared are
94 Z. Al Ani et al. / Process Safety and Environmental Protection 140 (2020) 86–99

Fig. 5. Case 4, maximization of CH4 Recovery and minimization of DI (a) The Pareto set at generation 200 for the process. (b–k) comparison of values of decision variables
for the process corresponding to the points on Pareto set in Fig. 5a.
Z. Al Ani et al. / Process Safety and Environmental Protection 140 (2020) 86–99 95

Fig. 6. The Pareto set (a) three-objective optimizaton (Case 5) (b) four-objective optimization (Case 6) study at generation 200.
96 Z. Al Ani et al. / Process Safety and Environmental Protection 140 (2020) 86–99

Table 3
Optimum values for operating conditions and objectives corresponding to points A, B, C, D and E shown in Fig. 5a.

Parameter A B C D E

% CH4 Recovery 93.22 94.92 95.90 96.03 96.30


DI 404.82 411.53 418.33 449.38 497.03
Tsourgas (K) 302.01 302.01 301.93 302.04 301.93
Psourgas (kPa) 4302.48 4302.48 4302.48 5065.12 7891.38
Fsourgas (MSm3 /day) 3.26 4.42 5.38 5.38 5.38
TleanDEPG (K) 279.13 277.82 277.76 277.69 277.76
TsemileanDEPG (K) 290.76 280.14 277.82 283.75 294.05

Fig. 8. Comparison of Pareto-optimal solutions for the two-objective (Case 2), three-
objective (Case 5) and four-objective (Case 6) optimization study at generation 200
Fig. 7. Comparison of Pareto-optimal solutions for the two-objective (Case), three- for the process.
objective (Case 5) and four-objective (Case 6) optimization study at generation 200
for the process.
Total Heat objective value in case 6 is also sensible from Fig. 7. In
general, DI values in case 5 are better compared to the other two
selected such that the value of %H2 S Removal does not vary by more cases, while %CH4 Recovery objective function results are relatively
than 0.01 %. In case 1, DI (calculated) is the damage index obtained close to each other for all the cases. DI objective function reduces
using the process conditions that generate the given %H2 S Removal as the %CH4 Recovery decreases as seen from the selected points
and Total Heat values while the same in case 5 is obtained by the in Table 4 in case 6 (except for point F”). For the same case, Total
optimization itself. The table is arranged in ascending order of %H2 S Heat value is increased with the increase in %H2 S Removal, which
Removal and note that the increasing sulfur Removal leads to higher is expected since more energy is needed for a higher pure gas.
values of Total Heat in both cases. Climbing energy requirements Table 5 compares the two-objective (Case 2, maximization of
as the sweet gas approaches very high purity is the reason for this. %H2 S Removal and minimization of DI), three-objective (Case 5,
However, the Total Heat values in both cases are not close. As is maximization of %H2 S Removal, and minimization of Total Heat
expected, the two-objective case has the better (lower) values for and DI) and four-objective (Case 6, maximization of %H2 S Removal
Total Heat at the same %H2 S Removal when compared with the and %CH4 Recovery, and minimization of Total Heat and DI) opti-
values in the three-objective study. This is observed as the three- mization for selected values of %H2 S Removal. The Pareto fronts for
objective case needs to optimize an additional objective and this all the cases involving the two objectives (i.e. %H2 S Removal and DI)
leads to sacrifices in the other objectives. Moving on to DI, their are plotted in Fig. 8. It is noted that the set of two-objective Pareto-
values also escalate as higher purity is targeted. This arises due to optimal solutions lies on the edge of the three-objective solution
the higher flow rates, temperatures and pressures present in the set. The points in the table are selected such that the %H2 S Removal
process. Since, large volumes of high pressure gases are involved, values in both cases are within 0.02 % of each other. This is done
DI values increase progressively and may approach dangerous val- to help study the difference between the objective values for both
ues if care is not taken. Notice how the DI values are way worse the cases. Like it was observed in the analysis of the two-objective
in the case 1 compared to case 5. DI in case 1 has very high values case, DI values increase slowly till 415 and then a sharp rise is seen.
which are generally discouraged while on the other hand, DI for The sudden change is observed around 99.75 % H2 S Removal and
case 5 are well within the acceptable ranges. This trend is observed similar results are noted in case 5. High values of DI are observed
because DI is an objective which is optimized in case 5 while it on approaching high levels of sweet gas purity since it requires
isn’t given any attention in case 1. So for the same %H2 S Removal large flow rates, temperatures and pressures and these directly
values, case 5 had lower DI but worse Total Heat values when com- contribute to DI. DI values in case 2 are better (lower) owing to
pared to case 1. In industry, multiple objectives are considered and the need to optimize a third objective in case 5 and as a result some
it is always better to go for multi-objective optimization over two- sort of loss needs to be incurred by the other objectives. For similar
objective optimization within time and processing constraints. For reasons however, the Total Heat is in case 5 is better than the two-
case 6, where four objectives are considered, it can be seen that a objective set. Since case 2 does not worry about the value of Total
small improvement is noticed with DI objective function in com- Heat obtained, it can be expended in favor of improving the objec-
parison to case 1, while the Total Heat objective value increased in tives considered. Case 5 on the other hand, evaluates Total Heat as a
case 6 compared to case 1 and 5 (see Table 4). The increase in the third objective and as a result its values are an improvement on the
Table 4
Comparison of the two-objective (Case 1), three-objective (Case 5) and four-objective (Case 6) optimization results for a few selected values of %H2 S Removal.

Case 1: % H2 S Removal vs Total Heat Case 5: H2 S Removal vs Total Heat vs DI Case 6: H2 S Removal vs Total Heat vs DI vs %CH4 Recovery

% H2 S Total Heat DI %CH4 % H2 S Total Heat %CH4 % H2 S Total Heat %CH4


Recovery DI Recovery DI
Removal (kJ/h) (calculated) Removal (kJ/h) Removal (kJ/h) Recovery
(calculated) (calculated)
A 97.8 −4.40E+06 676.15 95.81 A’ 97.79 −4.24E+06 419.71 95.7 A” 97.82 −2.00E+06 663.16 93.96
B 98.6 −4.23E+06 705.14 95.75 B’ 98.6 −4.18E+06 432.45 95.6 B” 98.61 −2.22E+06 713.46 95.68

Z. Al Ani et al. / Process Safety and Environmental Protection 140 (2020) 86–99
C 98.97 −4.05E+06 728.52 95.75 C’ 98.98 −3.97E+06 453.37 95.6 C” 98.98 −3.22E+06 699.78 95.11
D 99.32 −3.81E+06 748.83 95.62 D’ 99.32 −3.72E+06 476.54 95.62 D” 99.33 −3.20E+06 756.65 95.26
E 99.85 −2.36E+06 817.88 94.4 E’ 99.85 −2.29E+06 508.83 94.34 E” 99.85 5.74E+06 780.69 93.65
F 99.95 4.82E+05 822.46 92.43 F’ 99.95 6.29E+05 514.69 92.39 F” 99.95 9.56E+06 827.87 92.32

Table 5
Comparison of the two-objective (Case 2), three-objective (Case 5) and four-objective (Case 6) optimization results for a few selected values of %H2 S Removal.

Case 4: % H2 S Removal vs DI Case 5: % H2 S Removal vs Total Heat vs DI Case 6: % H2 S Removal vs Total Heat vs DI vs %CH4 Recovery

% H2 S Removal DI Total Heat %CH4 % H2 S DI Total Heat %CH4 % H2 S DI Total Heat (kJ/h) %CH4
(kJ/h) Recovery Removal (kJ/h) Recovery Removal Recovery
(calculated) (calculated) (calculated)

A 97.59 404.02 −1.62E+06 92.77 A’ 97.6 407.21 −2.61E+06 92.86 A” 97.61 671.92 −4.12E+06 95.78
B 98.14 404.9 −1.72E+06 92.75 B’ 98.15 408.1 −2.58E+06 92.87 B” 98.18 682.49 −3.79E+06 95.52
C 99.42 410.23 −1.93E+06 92.65 C’ 99.4 411.81 −1.96E+06 92.85 C” 99.43 760.92 −3.37E+06 95.57
D 99.6 412.27 −2.00E+06 92.6 D’ 99.59 414.71 −2.36E+06 92.77 D” 99.6 797.68 7.92E+06 95.26
E 99.91 482.7 2.10E+06 92.36 E’ 99.91 484.74 1.09E+06 92.38 E” 99.91 804.17 1.49E+05 92.69
F 99.93 503.46 −1.19E+06 92.46 F’ 99.93 505.75 −1.23E+06 92.49 F” 99.94 809.02 3.88E+06 92.49

97
98 Z. Al Ani et al. / Process Safety and Environmental Protection 140 (2020) 86–99

%CH4 Recovery
Case 6: % H2 S Removal vs Total Heat vs DI vs %CH4 Recovery

95.85
95.89
95.78
95.91

96.04
95.6
% H2 S Removal

96.87
97.34
97.61
97.26
99.56
97.91
682.39
671.92
686.82

759.36
681.07

806.92
DI
Total Heat (kJ/h)

−4.15E+06
−4.12E+06

−2.62E+06
−2.53E+06
−4.20E+06

−4.04E+06
Fig. 9. Comparison of Pareto-optimal solutions for the two-objective (Case 3), three-
objective (Case 5) and four-objective (Case 6) optimization study at generation 200

D”
A”
B”
C”

E”
F”
for the process.

Comparison of the two-objective (Case 3), three-objective (Case 5) and four-objective (Case 6) optimization results for a few selected values of Total Heat.
ones derived from case 2. No pattern was observed in the difference

%CH4 Recovery
in objective values between the two cases. This again is an example

(calculated)
of why three-objective optimization is better than using two objec-

95.77
95.76
95.78
95.38
92.86
92.87
tives, and is a more practical approach. For the four-objective case,
DI are much higher compared Case 4 and 5, as it varies from 661
to 829 (Fig. 8). This high increase in the DI is a result of adding the
fourth objective (maximization of %CH4 Recovery). As it can be seen

% H2 S Removal
from Table 5, point A” has a higher %CH4 Recovery value compared
to as that of point A, but at the same time, DI increased from 404.02

Case 5: % H2 S Removal vs Total Heat vs DI


for point A to 671.92 for A”. The increase in % H2 S Removal in case

97.44
97.83
97.79
97.93

98.15
97.6
6 resulted in an increase in values of DI and Total Heat objective
functions, which can be noticed as going from point A” to F”. On the

419.35
419.99
419.71
417.11
407.21
408.1
contrary, a reverse behavior in exhibited by %CH4 Recovery.
DI

Fig. 9 shows the Pareto-optimal solutions of the two-objective


(Case 3, minimization of Total Heat and DI), three-objective (Case
Total Heat (kJ/h)

5, maximization of %H2 S Removal, and minimization of Total Heat


and DI) and four-objective (Case 6, maximization of %H2 S Removal
−4.41E+06
−4.31E+06
−4.24E+06
−3.97E+06
−2.61E+06
−2.58E+06
and %CH4 Recovery, and minimization of Total Heat and DI) opti-
mization studies carried out. Few of these solutions are compared
in Table 6 using selected values of Total Heat of the process. Total
Heat values selected for comparison are always within 0.05 % of
D’
A’
B’
C’

E’
F’

each other for easy analysis. As was observed in the analysis of the
two-objective case, higher values of DI are obtained when more
%CH4 Recovery

energy is released, i.e. at very low Total Heat values. This is mainly
(calculated)

due to the high values of feed flow rate, temperature and pressure
existing in the process which may lead to accidents and hence have
95.79
95.69
95.62
95.26
92.76
92.78

high DI. The case 3 plot is very narrow and is only defined between
DI values of 404–420 and the process will be quite safe in these
conditions. Owing to this short range the difference between DI
% H2 S Removal

values of case 3 and case 5 is quite small but a trend does exist.
(calculated)

The DI values of case 3 are lower than that of case 5 understand-


ably, as case 5 needs to optimize three different objectives and so
97.43
97.64
97.53
97.49
97.58
97.59

some amount of each objective needs to be compromised for each


other. The calculated %H2 S Removal values for case 3 hover around
418.72

417.38
414.58
406.21
406.19

97 % as the constraint for sulfur content in the sweet gas is set at 4


418.3

ppm. Higher removal rates are observed in the three-objective case


DI

as it is optimized along with Total Heat and DI. In case 6, it can be


Case 3: Total Heat vs DI

Total Heat (kJ/h)

noticed that the Pareto front values for Total Heat objective function
are higher than the other two cases, because the first three points
−4.39E+06
−4.31E+06
−4.25E+06
−3.98E+06
−2.62E+06
−2.60E+06

(A”, B” and C”) are higher compared to the corresponding points in


case 3 and 5. The higher DI values are also observed in case 6 as it
is shown in Fig. 9. While a slight improvement is noticed in %CH4
Table 6

Recovery value in case 6 with approximately close %H2 S Removal


D
A
B
C

E
F

values when compared to case 3 and 5. Overall, as the Total Heat


Z. Al Ani et al. / Process Safety and Environmental Protection 140 (2020) 86–99 99

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