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An approach towards the design of a Petlyuk column using HYSYS

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AN APPROACH TOWARDS THE DESIGN OF A PETLYUK COLUMN USING HYSYS

Mustafa, M. Abbas1 and Wilson, J.A.2

1
Department of Chemical Engineering, Faculty of Engineering, University of Khartoum,
dr.mustafa.abbas@gmail.com
2
Chemical and Environmental Engineering,
Faculty of Engineering, the University of Nottingham, United Kingdom

Received Sep. 2011, accepted after revision Jan. 2012

‫ســت َْخـلـَص‬
ْ ‫ُمـ‬
‫ تخفيط استٖالك اىطاقت في عاٍ٘د‬ٚ‫ عَو اىَْٖذسُ٘ بدذ عي‬،ِ‫ ٍش اىسْي‬ٚ‫ ٗعي‬.‫يعذ اىتقطيشٗاحذ ٍِ أ قذً اىعَيياث اىَ٘حذة‬
‫ ٕي ابشاج اىتقطيش اىَشتبطت حشاسيا ً اىتي‬،‫ ٍِٗ االبشاج راث األَٕيت‬.‫ ظٖ٘س عذد ٍِ اىطشق غيش اىتقييذيت‬ٚ‫ اى‬ٙ‫اىتقطيشٍَا أد‬
ً‫ عْذ اىتفنيشفي استخذا‬،‫ فاُ أحذ اىش٘اغو اىشئيسيت‬،‫ ٗباىشغٌ ٍِ رىل‬.‫تتيح تخفيط مبيشاً في سأس اىَاه ٗتناىيف اىتشغيو‬
‫ فإُ بعط بشاٍح اىَحاماة‬،‫ رىل‬ٚ‫ عالٗة اى‬.ٌ‫ ٕ٘ عذً ٗخ٘د اخشاءاث سٖيت ٗساسخت ىيتصَي‬،ً‫ابشاج اىتقطيش اىَشتبطت حشاسيا‬
،‫ ٗباىتاىي تعشض ٕزٓ اى٘سقت ّٖح ىتصَيٌ عاٍ٘د اىبتيي٘ك‬.‫ حي٘ه أٗىيت‬ٚ‫ىيحاالث اىَستقشة ت٘اخٔ باشناىياث في اى٘ص٘ه اى‬
.‫ عبش استخذاً اىَحاماة اىذيْاٍينيت ببشّاٍح ٕايسيس‬،ً‫األمثش تعقيذا‬
ABSTRACT
Distillation is considered one of the oldest unit operations. Throughout the years, chemical
engineering designers have been working hard to reduce the energy consumption of columns
which has led to the development of many non-conventional methods. Of particular
importance are thermally coupled distillation columns (TCDC) which offer large savings in
capital and operating cost. The main concern, when contemplating the use of TCDC, is the
unavailability of easy and well established design procedures. Furthermore, some steady-state
simulators have given convergence problems particularly to establish the first solution. Thus,
this paper presents an approach for the design of the more complex Petlyuk column based on
dynamic simulation using HYSYS.

Keywords: Petlyuk column, simulation, design, HYSYS

Sudan Engineering Society Journal, March 2012, Volume 58; No.1 35

` AN APPROACH TOWARDS THE DESIGN OF A PETLYUK COLUMN USING HYSYS
INTRODUCTION
Distillation is a mature and well established
technology; however there is still the problem
of high energy consumption. Since energy
consumption is directly related to vapour flow
within the column, reduction in energy
consumption is possible through the reduction
of the vapour flow. This leads to a reduction in
the column diameter, with the use of a smaller
reboiler, which leads to a saving in capital cost.
However, effect of reducing vapour flow on
product quality needs to be considered.
1.1 Thermally Coupled Columns
A number of non-conventional arrangements
exist which use thermal coupling. The most
important incentive in the application of TCDCs
is that the side streams are drawn/added at the
most thermodynamically favourable points so
as to reduce the total energy consumption.
TCDC may be divided into 3 groups:
1. Direct thermally coupled system
Direct thermally coupled systems are also
referred to as systems with a side-rectifier. An
example for a ternary mixture is shown in
Figure 1. An impure vapour side-stream is
withdrawn from the first column, below the
feed tray, and purified in a side-rectifier, the
bottom of which is returned to the main
column [1].
2. Indirect thermally coupled system
Indirect thermally coupled systems are also
known as systems with a side-stripper. An
example for a ternary mixture is shown in
Figure 2. An impure liquid side-stream is
withdrawn from the first column above the
feed tray and purified in a side-stripper. The
top vapour product of the side-stripper is
returned to the first column [1].
3. Fully thermally coupled system (also
known as the Petlyuk column)
A Petlyuk column for a ternary mixture consists
of a pre-fractionator and a main column as
36 Sudan Engineering Society Journal,
shown in Figure 3. The main aim of the pre-
fractionator is to send all of the light
component and heavy component to the
distillate and bottoms respectively, but allow
the component of intermediate volatility to be
split between the overhead and bottoms.
Products from the pre-fractionator are directed
to appropriate trays in the main column. The
main column then produces the lightest
component as its distillate, the heaviest
component as bottom product and allows the
middle component to be drawn off as a side
stream with a very high purity. It is clear from
the figure that only one condenser and reboiler
are needed. As for reflux and boilup for the pre-
fractionator, they are obtained from the main
column. Theoretical studies have shown that
Petlyuk columns can save, on average, around
30% of energy costs compared with a
conventional arrangement [3].
A further advantage of the Petlyuk column is
that it could be constructed in a single shell
with an internal dividing wall as shown in Figure
4. This offer significant savings in field
construction costs [3]. Despite all the
advantages offered by thermally coupled
systems, designers have been reluctant to use
those kinds of systems. This reluctance can be
attributed mainly to potential operational
problems due to the bi-directional
interconnecting streams The Nigerian textile
industrial sector has been struggling for survival
Condenser Condenser
Product A
Product B
Main column
Side-rectifier
Feed Vapour
A,B,C
Liquid
Product C
Reboiler
Figure 1: Direct thermally coupled column
March 2012, Volume 58; No.1
 Mustafa, M. Abbas and Wilson, J.A.

Condenser 1.2 Simulation Package - HYSYS

Aspen HYSYS [5] provides an integrated
Product A
engineering environment in which all
applications work inside a common
Main Vapour operating environment. It also has the
column
advantage of been flexible, robust and
Feed interactive, thus making the process
Liquid
Side-stripper
A, B, C simulator very powerful and very easy to
use. One of the most important benefits of
Product B this package is its dynamic modelling option.
Product Once the model is set, the evaluation of the
Reboiler C response of each operation and the flow
Reboiler sheet interaction could be used to provide
Figure 2: Indirect thermally coupled column insight into the process.

Condenser 2 LITERATURE REVIEW

Work on thermally coupled columns started
Pre-fractionator mainly by focusing on determining design
Product A
parameters for minimum reflux ratios.
Vapour
Glinos and Malone [2] suggested using the
Main column minimum total vapour generated by
Liquid reboilers as a base for comparing between
Product B
Vapour different arrangements. They then proposed
A, B, C
useful expressions for calculating the
minimum vapour rates (at minimum reflux),
Liquid but no approach at that stage was
developed to determine the number of trays
Product C
needed in each column. Finn [6] also
Reboiler
established a procedure for calculating the
condenser/ reboiler loads at minimum reflux
Figure 3: Petlyuk Column ratio. The procedure developed again lacked
Condenser the initial design parameters required for a
rigorous simulation. Alatiqui and Luyben [7]
performed a more formal study of the
A design of indirect thermally coupled
columns. They found that better energy
B consumption could be achieved for feeds
A Feed
containing less than 20% of the intermediate
B
Internal Dividing wall component. The study was based on a
C
steady-state model using a trial and error
procedure to determine the optimal design
parameters. Throughout their study
C convergence problems were faced in some
Reboiler cases.

Figure 4: The dividing wall column

Sudan Engineering Society Journal, March 2012, Volume 58; No.1 37
` AN APPROACH TOWARDS THE DESIGN OF A PETLYUK COLUMN USING HYSYS
Cerda and Westerberg [8] developed short-
cut methods for the determination of
operating parameters for thermally coupled
columns; however Glinos and Malone [2]
think that the algorithm is unnecessarily
complicated. Triantafylou and Smith [3] then
produced a design model which provides a
basis for investigating the degrees of
freedom for a minimised overall vapour flow
(at a given reflux ratio) or number of plates.
It also provides a good initialisation for
rigorous simulation.
Ramírez-Corona et al. [9] proposed use of a
shortcut model for optimum design of
Petlyuk and dividing-wall distillation
systems; however, no rigorous calculations
are presented. Kim [10] further proposed a
semi-rigorous method for design of Petlyuk
column, nevertheless results provide only
basic information which could be fed into
commercial software. As an alternative
approach, Hernandez and Jimenez [1] used a
dynamic model to overcome the problem of
convergence. They first started by obtaining
a design for a direct conventional column as
shown in Figure 5. The final design of a
direct thermally coupled column is then
obtained as follows:
1 / Total number of stages in the first
column is equal to the number of stages of
column 1 plus the number of stages in
section 4 of column 2.
2 / Total number of stages in the side-
rectifier (Figure 1) is equal to the number of
stages in section 3 of column 2.
The position of the feed stream is fixed and
the side-draw is drawn from the bottom of
column 1 (corresponds, in the main column
of the direct thermally coupled system, to
the point between section 2 in column 1 and
the added section 4 of column 2).
38 Sudan Engineering Society Journal,
n-pentane
Stream 1
Upper Main
Column
A n-hexane
Feed 1
Column 1
B
n-hexane
Stream 2
Lower Main
Column
n-heptane
Figure 5: Direct sequence
Once the design is obtained, the procedure
continues by controlling the main column, while
varying the flowrate of the side-draw, until the
minimum duty is achieved. In this method the
design is fixed and although Hernandez and
Jimenez [1] have suggested adjustment of the
initial design after steady-state occurs (due to
the final composition of the products calculated
not matching the specifications of those
products), but no method to follow was given.
That means that the column could be over-
trayed or even the side-draw is not taken from
the optimum tray, at the main column, i.e.
where the maximum concentration of the
intermediate component occurs. So a
procedure has to be developed that looks more
deeply into those issues, and thus gives the
maximum savings in energy.
3. CASE STUDY
The feed (Table 1) enters the pre-fractionator
and the hexane is split between the light-key
component (pentane) at the top and the heavy-
key component (heptane) at the bottom. It is
then drawn out as a very pure component from
one of the trays of the main column as shown in
Figure 6. The four interconnecting streams
between the two columns mean that
establishing a steady-state design is particularly
challenging.
March 2012, Volume 58; No.1
 Mustafa, M. Abbas and Wilson, J.A.

Condenser The design procedure followed could be

summarised as follows:
Pre-fractionator i. Simplify Petlyuk column as shown in Figure
Stream 3 7 (Similar to Hernandez and Jimenez [1]
Stream A1 approach for direct thermally coupled
n-pentane
columns)
Main Column
Stream A ii. Apply short-cut methods in HYSYS to obtain
Feed 1
Stream 4 the initial design parameters of column 1, 2
Liquid
Stream B and 3.
n-hexane
iii. Perform rigorous simulation of column 1
(pre-fractionator) to obtain data for
Stream B1
streams A and B (2 side-draws from the
Stream 5 main column).
iv. Perform rigorous simulation of the main
n-heptane
Reboiler
column with its feed streams been streams
A1 and B1 but without the side draws from
Figure 6: Petlyuk column: Case study the main column been fed back into the
To have a feel of the problems faced by the pre-fractionator.
designer, one should try to attempt answering v. Couple the pre-fractionator with the main
the following questions: column using the dynamic facility.
1. How many plates are there in the pre- vi. Check the temperature profile to see if the
fractionator? columns are over-trayed.
2. How many plates are there in the main vii. Check the composition profile to see
column? whether stream A1 and B1 are entering the
3. On which plate does the feed enter the main column at the point which best
pre-fractionator? matches the composition of those streams.
4. On which plate do both feeds to the main
viii. Reduce number of trays in main column
column enter?
and repeat steps (vi and vii) until profiles
5. From which plate in the main column is the
are acceptable (no redundant stages).
side-draw taken?
6. How much is the distillate rate and the n-pentane
reflux ratio in the main column?
Stream 1 Column 2
A case study was chosen from the literature [1]
Upper Main
using feed specified in Table 1. Column
A
Table 1: Specification of feed
Feed 1 n-
Feed Column 1
hexane
Flowrate ( kgmol/h ) 45.4 B
Pressure ( kPa ) 101.33 n-hexane
Temperature ( o C ) 58 Stream 2
mole fraction of n-pentane 0.33 Column Lower Main
3 Column
mole fraction of n-hexane 0.33
mole fraction of n-heptane 0.33 n-heptane
Figure 7: Simplification of Petlyuk column

Sudan Engineering Society Journal, March 2012, Volume 58; No.1 39

` AN APPROACH TOWARDS THE DESIGN OF A PETLYUK COLUMN USING HYSYS

4. RESULTS AND DISCUSSION column 2 and 3 respectively. The purity of

the light and heavy key components was
The first step for simulating the fully
specified as 99%. The results of the short-cut
thermally coupled columns, also known as
method for column 2 and 3, together with
the Petlyuk columns, is to simplify it by
the light and heavy key components
dividing it into 3 columns using a
specified in each case as shown in Tables 3
conventional arrangement as shown in
and 4.
Figure 7 [3]. Column 1 roughly splits hexane
equally between the top and bottom Table 3: Results of the short-cut method for
product. Stream 1 is then sent to column 2 column 2
where pentane is recovered as the top Light key component Pentane
product and the hexane as the bottom Heavy key component Hexane
product. The same happens to Stream 3 but Flow rate of Stream 1 ( kgmol/h ) 22.56
hexane is separated as the distillate while Distillate flowrate ( kgmol/h ) 15.19
heptane is separated as the bottom product Bottoms flowrate ( kgmol/h ) 7.37
of column 3. Column 2 in this simplification Number of trays 21
represents the upper section of the main Feed tray location 9
column, while Column 3 represents the Reflux ratio 1
lower section of the main column.
4.1 Short-cut simulation Table 4: Results of the short-cut method for
column 3
The short-cut method is then implemented
Light key component Hexane
in HYSYS to get the initial design parameters
Heavy key component Heptane
for the three columns. For column 1, the
Flow rate of Stream 2 ( kgmol/h ) 22.84
light-key component was specified as n-
Distillate flowrate ( kgmol/h ) 7.69
hexane while n-heptane was specified as the
Bottoms flowrate ( kgmol/h ) 15.15
heavy-key component. The purity of hexane
Number of trays 23
in the top product was set to 33%, and that
Feed tray location 13
of the n-heptane in the bottoms to 65% just
Reflux ratio 2.86
to give roughly an equal split of hexane
between the products. As for the reflux
ratios, they were set to 1.3 times the 4.2 Rigorous simulation
minimum reflux ratio. The results are shown To simulate the pre-fractionator some more
in Table 2. information is needed about the flow rate and the
Table 2: Results of the short-cut method for composition of streams A and B (shown in Figures
column 1 6 & 7), which are basically the 2 side-draws from
the main column. Thus, rigorous data of streams A
Distillate flowrate ( kgmol/h ) 22.56 and B (Figure 7) were obtained for Column 1
Bottoms flowrate ( kgmol/h ) 22.84 previously simulated. The results of streams A and
Number of trays 12 B are shown in Table 5.
Feed tray location 10
Since all the information needed to simulate the
Reflux ratio 0.65
pre-fractionator was available, the pre-
fractionator was simulated rigorously using
The same procedure was followed for the HYSYS. For the main column, the number of trays
other two columns using the rigorous data in column 2 and column 3 gave the total number
for column 1 overheads/ bottoms as feed to of trays in the main column. The position of the

40 Sudan Engineering Society Journal, March 2012, Volume 58; No.1

 Mustafa, M. Abbas and Wilson, J.A.

feeds to column 2 and 3 gave the position of the Stream B drawn from main column 33
feed streams to the main column. The main at tray number
column was then simulated rigorously with its Stream 4 drawn from main column 20
feed streams been streams A1 and B1 (Figure 6), at tray number
already simulated from the pre-fractionator, but Reboiler duty ( kJ/h ) 2.07×106
without the side draws from the main column Flowrate of stream A1 ( kgmol/h ) 35.55
been fed back into the pre-fractionator. The final Composition of stream A1
and most exciting step then was to couple the Mole fraction of n-pentane 0.4569
Mole fraction of n-hexane 0.5431
pre-fractionator and the main column. Streams A
Mole fraction of n-heptane 4.07×10-5
and B were specified as recycle streams by adding
Flowrate of stream B1 ( kgmol/h ) 67.35
a recycle operation. The program was then
Composition of stream B1
allowed to run with products specified at 95%
Mole fraction of n-pentane 0.0892
purity. A new solution was reached as shown in
Mole fraction of n-hexane 0.606
Table 6.
Mole fraction of n-heptane 0.3048
Table 5: Rigorous data for stream A and B (Fig. 6)
Stream A B The next step was then to check the temperature
Flow rate ( kgmol/h ) 22 35.5 profile to see if the columns were over-trayed and
Temperature ( oC ) 57 76 then to check that stream A1 and B1 are entering
Concentration of pentane 0.26 0.08 the main column at the point which best matches
Concentration of hexane 0.74 0.73 the composition of those streams. For the number
Concentration of heptane 0.0 0.18 of stages in the pre-fractionator, it remained
unchanged at 12 stages, but the number of stages
on the main column reduced from 44 stages to 27
Table 6: Results of rigorous simulation of Petlyuk
stages (much more smother profile is produced
column
with no redundant stages). The best match
Total number of stages in pre- 12
fractionator between Stream A1 and the column was found,
Total number of stages in main 44 by examining the composition profile, at stage
column number 6 and as for Stream B1 the best match
Stream A1 entering main column at 9 was found at stage number 20. Furthermore,
tray number more cases were generated by changing the flow
Stream A drawn from main column 9 rate of Stream A. The results are shown in Table 7.
at tray number It is clear from the results that the duty is directly
Stream B1 entering the main column 33 proportional to the flow rate of stream A.
at tray number
Table 7: Comparison of different Petlyuk column cases
Flowrate of Reboiler duty The tray at which The tray at which Number of Total
stream A ( E+06 kJ/h) Stream A1 enters Stream B1 enters stages between number
(kgmol/h) (a) (b) a&b of trays
14 1.71 6 21 15 28
16 1.87 6 18 12 25
18 1.95 6 19 13 25
20 2.07 5 19 14 25
22 2.27 5 19 14 25
24 2.39 5 18 13 24
26 2.54 5 18 13 24
28 2.68 5 19 14 24
30 3 5 17 12 22

Sudan Engineering Society Journal, March 2012, Volume 58; No.1 41

` AN APPROACH TOWARDS THE DESIGN OF A PETLYUK COLUMN USING HYSYS

The convergence of the Petlyuk column was converging complex column configurations.
the biggest challenge to the author and it Although the design procedures established does
Figure 5.4.1 : Temprature profile of the main column
( before reducing the excess trays )

showed that the package was flexible

100

enough that it managed to solve this 95

complicated problem. On the other hand, 90

the savings in energy offered by the Petlyuk 85

column are clear from the previous table. 80

The energy consumption of the conventional

75

columns is 2.24752E+06 kJ/h, to obtain

Temperature ( C )
70
products with the same specifications. So

o
savings in energy could be seen for flowrates 65

of 20 kgmol/h and lower as shown in Table 60

8, however this has to be traded off versus 55

increase in the number of trays. 50

Table 8: Comparison of energy consumption of 45

Petlyuk column compared to conventional 40

distillation methods for flow rates of 20kgmol/h

35
and lower
30

Flow rate Duty Percentage of energy

1

9
11

13

15

17

19

21

23

25

27

29

31

33

35

37

39

41

43
Number of stages
(E+06 saved compared to the
(kgmol/h)
kJ/h) conventional methods (a)
Figure 5.4.2 : Temperature profile of the main column
( after removing the inefficient trays )

100
14 1.70784 21.8 %
16 1.87426 16.61 %
90

18 1.94611 13.41 %
20 2.07445 7.7 % 80
Temperature ( C )

70
Figures 8 and 9 show the change in the
o

temperature and composition profile for the

following case: Flow rate of stream A is equal to 60

22 kgmol/h, flow rate of stream B is equal to

35.5 kgmol/h and number of stages is equal to 50

27. Tray inefficiency is clearly evident with a

constant temperature/composition profile
40
existing across sections of the overtrayed
column.
30

5. CONCLUSION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

Number of stages

The use of thermally coupled distillation columns

has shown significant energy savings compared to
conventional distillation methods with values of
up to 22 % for a Petlyuk column in agreement
with Glinos et. al. [2]. The dynamic simulation
approach to thermally coupled columns has also
42 Sudan Engineering Society Journal,
(b)
Figure 8: Temperature profile of the main
column (a) with the column overtrayed, and
(b) after removing the inefficient trays
March 2012, Volume 58; No.1
 Figure 5.4.3 : Composition profile of hexane
( with the column overtrayed Mustafa,
) M. Abbas and Wilson, J.A.
1
costs, however it provides an idea of the
0.9
savings in energy offered by those columns and
takes the designer towards an optimum.
0.8
Furthermore, it was clear from the cases
investigated that the number of trays between
0.7

the positions of the 2 feed trays in the main

column roughly equalled the number of trays in
Mole fraction of hexane

0.6

the pre-fractionator. Thus the pre-fractionator

0.5
could be constructed with the main column in a
0.4
single shell with an internal dividing wall. This is of
particular importance due to the fact that the
0.3
procedure already established for designing the
Petlyuk column could be extended for designing
0.2

the ultimate Divided-wall column.

0.1
References
0
1. Hernandez, S., A. Jimenez, Design of optimal
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
41
43

Number of stages
Thermally-coupled Distillation systems using
(a)
Figure 5.4.4 : Composition profile of hexane in the main column
( after removing the inefficent trays )
a dynamic model, Trans I Chem E, 74, 357-
1
362, 1996.
0.9
2. Glinos, K., M.F. Malone, Optimality regions
for complex column alternatives in
0.8
distillation systems, Chem. Eng. Res. Des.,
0.7 66, 229-240, 1998.
3. Triantafyllou, C., R. Smith, The design and
Mole fraction of hexane

0.6

optimisation of fully thermally coupled

0.5
distillation columns, Trans IChemE, 70, 118-
0.4
132, 1992.
4. Hernández, S., J. G. Segovia-Hernández, V.
0.3
Rico-Ramírez, Thermodynamically
0.2
equivalent distillation schemes to the
Petlyuk column for ternary mixtures,
0.1
Energy, .31, 2176-2183, 2006.
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
5. Aspen HYSYS 3.2, Aspen Technology, Inc.,
Number of stages Ten Canal Park, Cambridge, MA 02141, USA,
(b) 2003.
6. Finn, A. J., Consider thermally coupled
Figure 9: Composition profile of hexane in the
distillation, Chem. Eng. Prog., 10 41-45,
main column (a) with the column overtrayed and
1993.
(b) after removing the inefficient trays
7. Alatiqui, I. M., W. L. Luyben, Alternative
distillation configurations for separating
proved very successful as a method for ternary mixtures with small concentrations
obtaining an initial design. HYSYS proved of intermediate in the feed, Ind. Eng. Chem.
very successful at not give a true optimum Proc. Des. Dev., 24, 500-506, 1985.
design, due to the inconsideration of capital
Sudan Engineering Society Journal, March 2012, Volume 58; No.1 43
 ` AN APPROACH TOWARDS THE DESIGN OF A PETLYUK COLUMN USING HYSYS

8. Cerda, K., M. F. Malone, Shortcut methods distillation systems using a shortcut

for complex distillation columns. 1. model, Chem. Eng. Res. Des., 88, 1405-
Minimum reflux, Ind. Eng Chem. Proc. Des. 1418, 2010.
Dev., 20, 546-557, 1981. 10. Kim, Y.H., Structural design of fully
9. Ramírez-Corona, N., A. Jiménez-Gutiérrez, thermally coupled distillation columns using
A. Castro-Agüero, V. Rico-Ramírez, a semi-rigorous model, Comput. Chem.
Optimum design of Petlyuk and divided-wall Eng., 29, 1555-1559.

44 Sudan Engineering Society Journal, March 2012, Volume 58; No.1

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