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Abstract
This paper presents an industrial case-study: the synthesis of partially thermally coupled and heat-integrated distillation systems
applied to the light ends separation section of a crude distillation plant. The distillation systems presented in this work employ the
thermal coupling and the heat-integration principles to significantly reduce the heat requirements with respect to the traditional simple
column train.
The work started from the simulation of the existing plant, by which the parameters of the system were identified. Then the possible
sequences of simple columns with sharp splits were identified for the considered application, and all the columns of the configurations
were designed. The corresponding thermally coupled sequences were obtained by using a simple procedure derived from the literature
and the heat-integrated partially coupled configuration (HIPC) was also considered.
In order to verify the examined distillation systems, all the simple and complex configurations were simulated by rigorous numerical
models. On the basis of the numerical simulations, the energy requirements for each configuration were evaluated. A rating of the dif-
ferent plants was then performed, based on the total annual cost, allowing to identify the best plant configuration. A thermally coupled
configuration showed the best performances for the considered separation.
Ó 2006 Elsevier Ltd. All rights reserved.
Keywords: Thermal coupling; Heat integration; Light ends separation; Distillation; Energy savings
1359-4311/$ - see front matter Ó 2006 Elsevier Ltd. All rights reserved.
doi:10.1016/j.applthermaleng.2006.02.045
1206 M. Mascia et al. / Applied Thermal Engineering 27 (2007) 1205–1211
However, the trend in process design is to utilize separa- a thermally coupled scheme all the columns operate at
tion schemes different from the sequences of simple columns, the same pressure, the opportunity of heat integration
in particular, that can provide significant reductions of heat can be considered if there simultaneously exists a middle
requirements [3–5]. The thermal coupling between two col- component captured in a rectifying section with a con-
umns in a sequence can be adopted to reduce the energy con- denser heavier than a middle component captured in a
sumption of the process [6,7]: the use of complex distillation stripping section with a reboiler [29]. The number of possi-
sequences, such as the thermally coupled ones, for the sepa- ble heat integration in a thermally coupled sequence
ration of multicomponent mixtures can offer energy savings increases as the number of components increases and only
around 30% with respect to the conventional distillation a single heat integration is allowed in a four-component
trains [8]. separation [29].
A thermally coupled sequence is obtained by removing In this work, the possible utilization of partially ther-
condensers and/or reboilers from a simple column configu- mally coupled configurations for the separation of a light
ration [9]. So the distinct feature of thermal coupled ends mixture was investigated and the possible heat inte-
schemes with respect to simple column ones is that in a gration was also considered.
thermally coupled configuration some units are intercon- In refining plants the light ends section is the process to
nected by thermal coupling streams [7]. separate the top products of the crude distillation unit.
Thermally coupled schemes have been proposed for Typically, the section is constituted by columns designed
some time [10], but their application was limited, mainly to separate LPG from intermediate and heavier products.
because of complexity in design and control of these struc-
tures [11], since the flexibility and the controllability of a 2. Design and simulation
system strongly depend on the number of units and on
their interconnections [12]. In the literature, several papers The flowsheet of the light ends process considered in this
have been presented on the application of the thermally work is showed in Fig. 1; as can be seen the plant is consti-
coupled configurations to multicomponent distillation sys- tuted by three simple columns in series. The main feed of
tems, most of which refer to the analysis of the perfor- the plant derives from a topping unit and contains different
mances and of the possible industrial applications in the amount of butane (A), pentane (B) hexane (C) and heptane
case of ternary mixtures to be separated [13–15]. Fully ther- (D). The feed is a saturated liquid with the characteristics
mally coupled schemes were also considered [16], along reported in Table 1.
with the use of side columns [17]. The high number of pos- A stream of LPG (manly constituted by butane) is sep-
sible configurations for multicomponent separations in the arated as top product in the first column of the sequence:
thermally coupled systems often has limited the research to the column has 28 sieve trays and a diameter of 2.5 m.
parametric studies referred to specific mixtures [18,19]. The bottom product of this unit is sent to the second col-
Recently, it has been extensively shown that the control
of thermally coupled schemes may be not a more difficult
task than that in conventional distillation trains [20]: the
control properties of such integrated schemes of separation
were investigated [21,22] and the control analysis of a ther-
mally coupled distillation plant has been presented for a C1
four component separation [23].
As a result, current research efforts are focused on the C3
design of new configurations for the separation of mixtures
with more than three components [24,25]. Studies on the C2
synthesis of thermally coupled distillation trains applied
to complex mixtures have been recently presented in the lit-
erature [26,27].
Although it is a promising strategy, the application of
thermally coupled schemes to a particular separation Fig. 1. Schematic representation of the light ends separation plant
always has to be tested: as reported in the literature, the considered in this work.
introduction of thermal couplings does not necessarily lead
to higher efficiencies than those of conventional distillation
sequences but the efficiency depends on the mixture and on Table 1
the composition [13]. Characteristics of the feed mixture
Further reductions in the heat requirements of a distilla- Composition (mole frac.)
tion plant can be achieved if heat integrations between two C4 (n-buthane) 0.33 Temperature [°C] 130
column sections in the thermally coupled sequence are C5 (n-pentane) 0.35 Pressure [bar] 5
allowed: in this case the heat removed from a condenser C6 (n-hexane) 0.16 Vapour fraction 0
C7 (n-heptane) 0.16 Flow rate [kmol/h] 1250
is utilized in a reboiler of the same sequence [28]. Since in
M. Mascia et al. / Applied Thermal Engineering 27 (2007) 1205–1211 1207
umn, (32 sieve trays, D = 3 m) from which a middle gaso- alternative configurations in Fig. 2. The corresponding
line, mainly heptane, is obtained as bottom product. The thermally coupled schemes were also considered: Fig. 3
third column of the sequence (34 sieve trays, D = 2 m) sep- shows the flowsheets of these configurations. The only
arates the pentane, as top product, from a stream of light heat-integrated configuration allowed for a four compo-
gasoline (hexane). The condensers of the plant are shell nent separation was also studied (see Fig. 3).
and tube exchangers, whereas the reboilers are kettle-type: The design of each column in the different sequences was
in each column, the cold utility is cooling water, whereas performed and in particular the number of plates, the min-
saturated steam is the hot one. imum reflux ratio and the boil-up ratio of each column
Based on field data, a rigorous simulation of the separa- were estimated by the Fenske–Underwood–Gilliland
tion train was performed by the commercial software (FUG) short-cut method. All the units were initially
Aspen Plus: the RADFRAC model was utilized to simulate designed with a reflux ratio equal to 1.2 the minimum value
all the units. The model allows the stage by stage calcula- and considering the purity of each component in the rele-
tion of flow rates, compositions and temperatures in each vant stream equal to 98%.
column section; the Wilson equation was adopted for the The design of the thermally coupled columns was per-
calculation of the activity coefficients in liquid phase, formed according to Carlberg and Westerberg suggestions
whereas ideal behaviour was assumed for the vapour [30], and it can be obtained from the conventional distilla-
phase. The difference between the values of temperatures, tion sequences shown in Figs. 1 and 2 by removing con-
flow rates and composition obtained by the model and densers and (or) reboilers. For example, the sequence 6 in
those measured in the plant never exceeded 5%. Fig. 3 was obtained by using a thermal link in the vapor
From the results of the simulation the values of relative phase in the conventional direct distillation sequence
volatility were obtained, which were utilized to design and (Fig. 2, number 4), which eliminates the reboilers in the col-
simulate the different configurations investigated in this umns C1 and C2. In the same way, the design of the
work. sequence number 8 in Fig. 3 was obtained from the conven-
In classical simple column sequences usually adopted in tional indirect distillation sequence (Fig. 2, number 3) by
the industry, the pressure of the different units is optimized removing the condensers of the columns C1 and C2, and
separately, depending on the particular separation carried by introducing a thermal coupling in the liquid phase.
out in the column. However, the thermally coupled config- Then, a rigorous simulation of the different configurations
urations tested in this work must operate at the same nom- was performed by using the commercial software Aspen
inal pressure; thus, in order to compare the different Plus: the RADFRAC model, already utilized in the simula-
solutions, the design of the units in all the configurations tion of the existing plant, was utilized to simulate all the
studied was performed at a pressure of 5 bar. units. The Wilson equation, which was successfully used
Five flowsheet configurations of simple columns were in the plant simulation, was adopted for the calculation
compared in this work: the sequence in Fig. 1 and the four of the activity coefficients in liquid phase, whereas ideal
2
3
C2 C3
C1
C2
C3
C1
C1 C2
5
C2
C1
4 C3 C3
8
C3
C1 C2
7
6
C3 C2
C2 C1
C1
C3
C2
C1 C1 10 C2
C3 C1
C2 C3 11
C3
9
Fig. 3. Sequences of partially coupled and heat-integrated (11) distillation columns examined in this work.
behaviour was assumed for the vapour phase. In all the The capital cost of the columns was obtained by the
examined sequences, the number of stages obtained by Peter’s cost diagrams [31], considering sieve tray columns.
the FUG short cut method was utilized. The capital cost of condensers and reboilers was evalu-
The values of reflux ratio in the sequences of simple col- ated by considering the heat exchange area A:
umns were optimized through a sensitivity analysis in each
column, in order to fit the field data of flow rates and Q
A¼ ð4Þ
compositions. U d DT LM
A similar procedure was adopted for the thermally cou-
pled sequences: for example, starting from the values of the where Q is the duty of the exchanger and Ud is the average
sequence 1, the vapour flow rates of the column C2 and the exchange coefficient. The values of Ud were calculated from
liquid flow rate of the column C3 in the thermally coupled field data of heat exchange area, temperatures and heat du-
scheme 9 were adjusted until the minimum duty was ties; they were assumed equal to a mean value of 1800 kJ/
obtained, flow rates and compositions of the product m2 h °C for the condensers and 2100 kJ/m2 h °C for the
streams being the same. reboilers.
The duty of reboilers and condensers and the column All the capital costs were actualized to year 2004 by the
diameters were obtained from the simulations and utilized Marshall and Swift index.
to calculate both energy and capital costs of each plant The cost [$/year] of the utilities was estimated as
configuration.
In order to calculate the height of the columns, the tray cost ¼ W C H y ð5Þ
efficiency (g) of each column section was calculated from
where W is the water or steam flow rate [ton/h], C is the
the values of the average viscosity (l) of feed, the average
water or steam price [$/ton] and Hy is the annual running
relative volatility (a), the weir height (hw = 50 mm) and
time, assumed equal to 8000 h/year].
the ratio between liquid and vapour flow rates (L/V) in
The total annual cost TAC [$/year], by considering a lin-
the section by the following equation [31]:
ear depletion of the investment and a lifetime of 10 years,
logðgÞ ¼ 1:67 0:25 logðalÞ þ 0:3 logðL=V Þ þ 0:3hw ð2Þ can be obtained as
The height H [m] of the columns was then calculated as TAC ¼ capital cost=10 þ utilities cost ð6Þ
a function of the number (N) of plates:
The prices of utilities adopted in this work are summa-
H ¼ ðN 1Þ 0:6 þ 6 ð3Þ rized in Table 2 and are based on European prices [32].
M. Mascia et al. / Applied Thermal Engineering 27 (2007) 1205–1211 1209
Table 3
Design parameters obtained for the sequences examined
Sequence Number of theoretical plates Diameter (m)
Column 1 Column 2 Column 3 Column 1 Column 2 Column 3
1 18 23 26 2.44 3.22 2.01
2 28 19 23 2.86 1.96 1.96
3 28 26 19 2.86 2.44 1.82
4 18 29 23 2.44 2.70 2.80
5 23 19 25 2.51 1.82 2.91
6 18 23 26 2.44 2.79 4.10
7 28 19 23 2.86 3.07 2.22
8 28 26 19 2.86 3.39 3.33
9 18 29 23 2.43 3.39 3.33
10 23 19 25 2.50 3.07 3.13
11 30 12 25 2.50 2.83 2.43
1210 M. Mascia et al. / Applied Thermal Engineering 27 (2007) 1205–1211
20
18
16
14
Duties (Mkcal/h)
12
10
0
1 2 3 4 5 6 7 8 9 10 11
Number of Sequences
Fig. 4. Condenser (empty bars) and reboiler (full bars) duties for all the sequences considered.
0.9
0.8
0.7
Normalised TAC
0.6
0.5
0.4
0.3
0.2
0.1
0
1 2 3 4 5 6 7 8 9 10 11
Number of Sequences
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