Xavi - Gasulla - Distillation Workshop

DISTILLATION WORKSHOP
Xavier Gasulla Navarro 12/11/2023
Introduction
For this deliverable, we will explore different distillation models to be utilized in Aspen HYSYS,
employing the SRK fluid package. The specific components under scrutiny are outlined in the
accompanying table, which also provides the expected molar fractions for the input stream
(FEED) and their corresponding boiling points. These boiling points are extracted from Aspen
HYSYS under 1 atmosphere.
Table 1 Components and Associated Properties
Components Flow rate [kmol/h] Boiling point [ºC] ( Q1 )

Propane 7,3 -42,10
i-butane 16,5 -11,72
n-butane 27,5 -0,50
i-Pentane 17,7 27,88
n-Pentane 31 36,06
The inclusion of boiling points is crucial for assessing the relative volatility of components and
determining optimal temperatures for separations. This analysis will enable us to identify the
most and least volatile components, enhancing our understanding of distillation processes and
aiding decision-making regarding operational conditions.
Component Splitter
In the upcoming distillation process, we will employ the Aspen HYSYS Component Splitter
model to achieve our separation goals. The Component Splitter model in Aspen HYSYS is a tool
designed for dividing a single stream into multiple product streams based on user-defined
specifications.
Figure 1 Component Splitter
For this specific distillation, we have set the following parameters:
- A pressure drop in the column of 0.4 bar.

- The pressure is fixed to allow the use of cooling water in the column condenser at the
minimum delta approach.
- Assumptions include:
 The bottom stream exclusively comprises C5 components, with all other

components exiting through the column head.
 The top stream is defined as saturated liquid at the lowest possible temperature,
considering the available cooling utilities.
 The bottom stream operates under bubble point conditions.
 The feed stream is saturated liquid and shares the same pressure as the bottom
stream.
In our operational setup, we are equipped with cooling water at a temperature of 45 °C. The
condenser operates with a minimum approach temperature of 10 °C
Table 2 Conditions of FEED
(Q2 ) Vapour Fraction 0,00

(Q2 ) Temperature [ºC] 78,51
(Q2 ) Pressure [kPa] 848,9
Molar Flow[kmol/h] 100,00
Master Comp Mole Frac (n-Pentane) 0,31
Master Comp Mole Frac (n-Butane) 0,275
Master Comp Mole Frac (i-Pentane) 0,177
Master Comp Mole Frac (i-Butane) 0,165
Master Comp Mole Frac (Propane) 7,30e-
002
Table 3 Conditions TOP

Molar Flow 51,30
Master Comp Mole Frac (Propane) 0,14
Table 4 Conditions BOTTOM

(Q2 ) Temperature [ºC] 113
Molar Flow 48,70
Master Comp Mole Frac (Propane) 0,00
As indicated in Table 3, we establish that the stream is in a saturated liquid state (vapor fraction
= 0) at a temperature of 55°C, which is the minimum required for cooling the Top stream. From
this point, we derive the column pressure, taking into account a pressure drop of 40 kPa. This
allows us to determine the pressures of both the Feed and the Bottom. (Q2 )
It's worth noting that the Top is specified with a vapor fraction of 0, indicating saturated liquid
conditions. This decision is driven by the fact that, as we fix the pressure, an increase in vapor
fraction would lead to higher temperatures. This adjustment is crucial to comply with the water
utility specifications. The same principle applies to the Bottom, ensuring it remains at the bubble
point before reaching saturated vapor conditions. (Q3 )
We also need to observe that the energy balance is maintained. Using the energy balance
equation, Q_in = Q_out, we observe that this balance holds in the Component Splitter. (Q4 )
𝑘𝑗
𝑄𝐹𝐸𝐸𝐷 = −1,519𝑒7 ℎ
𝑘𝑗
𝑄100 = 1,526𝑒5
ℎ
𝑘𝑗
𝑄𝑇𝑂𝑃 = −7,727e6 ℎ
𝑘𝑗
𝑄𝐵𝑂𝑇𝑇𝑂𝑀 = −7,762𝑒6 ℎ
𝑄𝑖𝑛 = 𝑄𝑜𝑢𝑡 → 𝑄𝐹𝐸𝐸𝐷 + 𝑄100 = 𝑄𝑇𝑂𝑃 + 𝑄𝐵𝑂𝑇𝑇𝑂𝑀
−1,519𝑒7 + 1,526𝑒5 + 7,727𝑒6 + 7,762𝑒6 = 0 (Q4 )
Shortcut Colum
We are currently employing a shortcut distillation method. This involves working with a
saturated liquid feed of specified composition at 9 bar. The condenser operates at 7,9 bar, and
there is a 0,4 bar pressure drop through the column. Additionally, we consider a molar fraction
of n-butane in the bottoms of 0,01 and a molar fraction of i-pentane in the distillate of 0,02.
In essence, the shortcut distillation method is a simplified approach that streamlines the
estimation of component separation in a distillation process. It allows for quicker analyses by
making certain assumptions and utilizing simplified calculations, though it may sacrifice some
precision compared to more detailed methods.
The following product specifications must also be adhered to:
- Maximum 3% weight of iso-pentane in the distillate.

- Maximum 1% weight of normal-butane in the bottoms.
Figure 2 Shortcut Colum
Table 5 Conditions of Feed_2
Temperature [ºC] 81,31

Pressure [kPa] 900,00
Molar Flow [kmol/h] 100,00
Master Comp Mass Frac (i-Butane) 0,15
Master Comp Mass Frac (i-Pentane) 0,19
Master Comp Mass Frac (n-Butane) 0,25
Master Comp Mass Frac (n-Pentane) 0,35
Master Comp Mass Frac (Propane) 0,05
Table 6 Conditions of Distillation

(Q6 ) Master Comp Mass Frac (i-Pentane) 0,02
Table 7 Conditions of Bottoms

(Q6 ) Master Comp Mass Frac (n-Butane) 0,008
In Table 5, the feed input data for the shortcut is detailed. Based on this information and the
previously specified requirements, a minimum reflux ratio of 1.272 is calculated. Achieving such
a minimum reflux ratio would theoretically demand an infinite number of trays (Q5 ). To facilitate
convergence in the shortcut method, a reflux ratio 1.3 times the minimum is employed. This
adjustment ensures compliance with water utility specifications Table 6 and meets the criteria
for the heavy key and light keys (Table 6 & Table 7 ) (Q6 ) . Considering all factors, the column is
determined to require 22 plates, with the optimal feed plate identified as the 9th plate in the
sequence (Q7 ).
Rigorous Column
Now, design the rigorous column using the identical feed composition as that employed in the
shortcut column, Table 5. Similarly, maintain consistent pressures throughout the column.
Adhere to the specifications established during the design of the shortcut column, including
the number of stages and the selection of the feed tray.
Figure 3 Rigorous Column
Table 8 Conditions of OVH_COLUMN

(Q8 ) Master Comp Mass Frac (i-Pentane) 0,02
Table 9 Conditions of BOTTOMS_COLUMN

(Q8 ) Master Comp Mass Frac (n-Butane) 0,01
As observed in the tables, compliance is achieved both with the utilities and with the
contamination percentages in the streams. (Q8 )
Considering the two specifications that we can indicate in the column are the maximum
percentages it can have for overheads and bottoms. We will observe the differences in the
condenser and reboiler, both in terms of heat duties and reflux ratio.
Optimal stage 7th stage 11th ratio 7vs9 ratio 11vs9

Feed 9th
Condeser Heat (kJ/h) 2613277,57 2639502,40 2700339,72 1,00% 3,33%
Reboiler Heat (kJ/h) 2682248,56 2707601,50 2770256,32 0,95% 3,28%
Reflux ratio 1,627 1,673 1,764 2,83% 8,42%
Observations and Explanations:
Condenser Heat:
- Shifting the feed stage to the 7th stage results in a 1% increase. This may be attributed
to a change in the feed composition, requiring more energy to condense the
components in the condenser.
- Moving the feed stage to the 11th stage increases by 3,33%. This could indicate that
having the feed closer to the condenser requires less energy for component
condensation.
Reboiler Heat:
- Changing the feed stage to the 7th stage increases the reboiler heat by 0,95%. This might
be due to a higher load of less volatile components, requiring more energy for
vaporization in the reboiler.
- Shifting the feed stage to the 11th stage increments the reboiler heat by 3,28%. This
increase may be attributed to a lower load of less volatile components, needing more
energy for vaporization.
Reflux Ratio:
- The 2,83% decrease in reflux ratio when moving from the 9th to the 7th stage may be
explained by less vapor condensation in the condenser, leading to a reduction in the
amount of liquid returned to the column.
- The 8,42% increase in reflux ratio when moving from the 9th to the 11th stage suggests
more vapor condensation, generating more liquid reflux and improving separation
efficiency.
These explanations indicate how the feed stage position influences the column load and,
consequently, its energy requirements and separation efficiency. (Q9 )
To analyze the optimal feed stage among the stages studied, let's plot the temperature, pressure,
liquid and vapor molar flowrates, and provide commentary on the results. Note that Stage 0
represents the condenser, and Stage 23 represents the reboiler. Stage 23 represents the reboiler.
110
100
Temperatura [C]
90
80
70
60
50
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
stage
Figure 4 Temperature Profile
840
830
820
Pressure [kPa]
810
800
790
780
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
stage
Figure 5 Pressure Profile

200
180
160
Net liquid [kmol/h] 140
120
100
80
Net liquid [kmol/h] Net vapour [kmol/h]
60
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
stage
Figure 6 Liquid Flowrate & Liquid Flowrate Profile
Temperature Profile Figure 4:
The temperature gradually increases from the condenser (Stage 0) to the reboiler (Stage 23).
This is expected in a distillation column where heat is added to vaporize the components.
Pressure Profile Figure 5:
The pressure remains relatively constant throughout the column until the reboiler, where it
drops to zero. This aligns with the expected behaviour of a distillation column.
Liquid Flowrate Profile Figure 6:
The net liquid flowrate experiences a substantial decrease as we move up the distillation column.
This is because, in a distillation process, the liquid feed is gradually vaporized as it ascends the
column. At the reboiler (Stage 23), all remaining liquid is vaporized, resulting in a sharp drop to
zero.
Vapor Flowrate Profile Figure 6:
The net vapor flowrate, on the other hand, shows a more linear increase. This is because vapor
is generated at each stage as the liquid is vaporized. The vapor produced at each stage combines
with the vapor from the previous stages, leading to a more gradual and linear increase in the net
vapor flowrate. (Q10 )
Question
Q1 Fill the table with the boiling point of the pure components at 1 atm
Q2 What are the conditions of feed, top, and bottom stream?
Q3 Why is the top stream defined as saturated liquid and not saturated vapor? What
would happen if we defined it as saturated vapor?
Q4 Check that the energy balance is maintained.
Q5 What is the minimum reflux? How many stages do we need to operate the column at
minimum reflux?
Q6 Does the product fulfill the specifications?
Q7 How many stages does the column need? In which stage is recommended to introduce
the feed?
Q8 Is the product within specifications?
Q9 Study how the feed stage affects the energy use of the column. Consider +- 2 positions
to change the feeding and display the condenser heat, reboiler heat, and reflux ratio.
Comment the results
Q10 For the optimal feed stage among the ones studied, plot the temperature,
pressure, liquid and vapor molar flowrate, and comment the results.
*** All questions are answered, indicating the (Qn) attached with a hyperlink. ***

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DISTILLATION WORKSHOP

Xavier Gasulla Navarro 12/11/2023

Components Flow rate [kmol/h] Boiling point [ºC] ( Q1 )

Figure 1 Component Splitter

For this specific distillation, we have set the following parameters:

- A pressure drop in the column of 0.4 bar.

 The bottom stream exclusively comprises C5 components, with all other

Table 2 Conditions of FEED

(Q2 ) Vapour Fraction 0,00

Table 3 Conditions TOP

(Q2 ) Vapour Fraction 0,00

Table 4 Conditions BOTTOM

(Q2 ) Vapour Fraction 0,00

The following product specifications must also be adhered to:

- Maximum 3% weight of iso-pentane in the distillate.

Figure 2 Shortcut Colum

Table 5 Conditions of Feed_2

Temperature [ºC] 81,31

Table 6 Conditions of Distillation

(Q6 ) Temperature [ºC] 54,85

Temperature [ºC] 111,4

Figure 3 Rigorous Column

Table 8 Conditions of OVH_COLUMN

(Q8 ) Temperature [ºC] 54,98

Table 9 Conditions of BOTTOMS_COLUMN

Temperature [ºC] 111,00

Optimal stage 7th stage 11th ratio 7vs9 ratio 11vs9

Observations and Explanations:

Figure 4 Temperature Profile

Figure 5 Pressure Profile

Net liquid [kmol/h] 140

Figure 6 Liquid Flowrate & Liquid Flowrate Profile

Temperature Profile Figure 4:

Pressure Profile Figure 5:

Liquid Flowrate Profile Figure 6:

Vapor Flowrate Profile Figure 6:

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