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IFAC PapersOnLine 53-1
Vapor Recompression C(2020) 117–122
3 Splitter: Design and Control
Vapor
Vapor Recompression
Recompression C
C 3 Splitter: Design and Control
Vapor Recompression C 3 Splitter:
Splitter: Design
Design and
and Control
Control
Aditya Anand*, Vivek 3 Kumar**, NitinKaistha***
Vapor
VaporRecompression
Recompression CC3 3Kumar**,
Splitter:
Splitter: Design
Design and Control
Control
Vapor Recompression
Aditya Anand*, C3 Kumar**,
Vivek
Aditya Anand*, Vivek  Splitter:NitinKaistha***
Design and Control
NitinKaistha***
*Chemical Engineering, Aditya Anand*, Indian Institute Vivek of Kumar**,
Technology NitinKaistha***
Kanpur, Kanpur, India 208016
Aditya
Aditya Anand*,
Anand*, Vivek
Vivek Kumar**, NitinKaistha***
*Chemical Engineering, Indian (e-mail:Institute ofKumar**,
Technology
adianand@iitk.ac.in) NitinKaistha***
Kanpur, Kanpur, India 208016
*Chemical Aditya Anand*,
Engineering, Indian Vivek of
Institute Kumar**,
 Technology NitinKaistha***
Kanpur, Kanpur, India 208016
*Chemical
**Chemical Engineering,
Engineering, Indian
Indian(e-mail:Institute
Instituteadianand@iitk.ac.in)
of
of
of Technology
Technology Kanpur,
Kanpur,Kanpur,Kanpur,India India 208016
India208016208016
*Chemical
*Chemical Engineering,
Engineering, Indian (e-mail:
Indian Institute adianand@iitk.ac.in)
Institute ofTechnology
TechnologyKanpur, Kanpur, Kanpur,
Kanpur, India 208016
**Chemical
*Chemical Engineering, Engineering,Indian Indian(e-mail:
(e-mail: Institute
Institute adianand@iitk.ac.in)
of
of Technology
Technology
vivekiit09@gmail.com) Kanpur,
Kanpur, Kanpur,
Kanpur, India
India 208016
208016
**Chemical (e-mail:
(e-mail: adianand@iitk.ac.in)
adianand@iitk.ac.in)
**Chemical Engineering,
***Chemical Engineering,
Engineering,
Indian
(e-mail:
Indian(e-mail:
Indian
Institute of Technology
vivekiit09@gmail.com)
Institute of Technology
adianand@iitk.ac.in)
Institute of Technology
Kanpur,
Kanpur,
Kanpur,
Kanpur,
Kanpur,
Kanpur,
India
India
India
208016
208016
208016
**Chemical
**Chemical Engineering,
Engineering, Indian
Indian
(e-mail: Institute
Institute ofofTechnology
TechnologyKanpur,
vivekiit09@gmail.com) Kanpur, Kanpur, India India 208016
208016
***Chemical
**Chemical Engineering,
(Tel:
Engineering, Indian
(e-mail:
+91-512-2597513;
Indian Institute
Institute of
of Technology
vivekiit09@gmail.com)
email: Kanpur,
nkaistha@iitk.ac.in)
Technology Kanpur, Kanpur,
Kanpur, India
India 208016
208016
***Chemical Engineering, (e-mail:
(e-mail:
Indian Institutevivekiit09@gmail.com)
vivekiit09@gmail.com)
of Technology Kanpur, Kanpur, India 208016
***Chemical (Tel: +91-512-2597513;
Engineering, Indian
(e-mail: Institute email:
of nkaistha@iitk.ac.in)
Technology
vivekiit09@gmail.com) Kanpur, Kanpur, India 208016
***Chemical
***Chemical Engineering,
Engineering, IndianInstitute
(Tel: +91-512-2597513;
Indian Institute ofTechnology
Technology
email:
of Kanpur, Kanpur, India
nkaistha@iitk.ac.in)
Kanpur, India 208016
208016
Abstract: Vapor recompression ***Chemical(VRC) (VRC)
Engineering,based
(Tel:
(Tel: heat integration
+91-512-2597513;
Indian
+91-512-2597513; Instituteisof is usually
email: employed
nkaistha@iitk.ac.in)
Technology
email: Kanpur,
nkaistha@iitk.ac.in)for purifying
Kanpur, India a propylene-propane
208016 mixture in
Abstract:
a C3 splitter. Vapor A fixed recompression
speed drive(VRC) (Tel:
or a(Tel: based
variable+91-512-2597513;
heat
speed integration
drive email:
compressor usually nkaistha@iitk.ac.in)
employed
may be for
employed purifying
for a
overheadpropylene-propane
vapor mixture In
recompression. in
Abstract: Vapor recompression based heat integration is
+91-512-2597513; email: nkaistha@iitk.ac.in)usually employed for purifying a propylene-propane mixture in
athis C3Abstract:
Abstract: splitter. Vapor A fixed speed
recompression drive or
(VRC) a variable
based speed
heat drive
integration compressor
is usually may
employedbe employed
for for
purifying overhead
a vapor
propylene-propane recompression.
mixture In
in
C33 work,
aAbstract:splitter. economic
Vapor Vapor
A fixed controllable
recompression
speed
recompression drive(VRC) designs
(VRC)
or a variable
based for heat
based the
heat
speed two compressor
integration
drive
integration compressor typesmay
isisusually
usually in abeVRC
employed
employed C3purifying
for
employed
for splitter
purifying are obtained vaporvia
aa propylene-propane
for overhead propylene-propane rigorousmixture
recompression. steady
mixture inIn
in
athis
C
state work,
splitter.
and economic
pressureA fixed controllable
speed
driven drive
closed designs
or
loop a variable
dynamic for the
speed two
simulations. compressor
drive compressor
Aissimple types mayin
dual abe VRC
employedC splitter
for are
overhead obtained vapor via rigorous
recompression. steadyIn
a C3awork,
this 3 C3 splitter.
Abstract:
splitter. Vapor
economic
A fixedA fixed
recompression speed
controllable
speed drive
drive (VRC) or
designs
or abased
variable
a variable for heat
the speed
speed two drivecompressor
integration
compressor
drive compressor
usually
types mayin aended
may
employed be
be VRC decentralized
employed
for
employed
3
C33purifying
splitter
for acomposition
for overhead
are
overhead vapor
propylene-propane
obtained vaporvia control
recompression.
rigorous system
mixture
recompression. steady is
InIn
in
state
this
shown
a C3thisand
work,
splitter. pressure
towork, economic
provide Aeconomic
fixed driven
speed closed
controllable
effective column
controllable
drive looploop
designs
or dynamic
regulation.
adesigns
variableforforthe simulations.
thetwo
The
speed compressor
economic
two drive Acontrollable
compressor
compressorsimple
types dual
types
may aended
inindesign
a VRC
be VRC decentralized
C
C33 splitter
results
employed indicate
splitter
for arecomposition
are
overhead obtained
that
obtainedwhen
vapor via
via a control
rigorous
fixed
rigorous system
speed
recompression. steady
drive
steady is
In
this
state
shown work,
and to economic
pressure
provide controllable
driven
effective closed
column designs dynamic
regulation. for the
The two
simulations. compressor
economic A types
simple
controllable in
dual a VRC
ended
design C splitter
decentralized
3
results indicate are obtained
composition
that when via
a rigorous
control
fixed system
speed steady
driveis
state and
state
compressor
this work, pressure
and ispressure
economic used, driven
driven closed
significant
controllable closed looploop
pressure
designs dynamic
dynamic
drop
for the simulations.
mustsimulations.
two be provided
compressor A A simple
simple
across
types dual
dual
the ended
ended decentralized
compressor
indesign
aended decentralized
VRCresults suction
C3 splitter composition
composition
throttling
arecomposition
obtained valve
via control
control for
rigorous system
system
sufficient is
steady is
state
shown and
compressor to pressure
provide driven
effective closed
column loop dynamic
regulation. simulations.
The economic Acontrollable
simple dual decentralized
indicate that when aa control
fixed system
speed driveis
shownshown
rangeability
state and tois
to pressure
provide used,
provide
towards significant
effective
effective
worst-case
driven column
closed pressure
column regulation.
disturbance
loop droprejection.
regulation.
dynamic must
The
simulations.be
Theeconomic provided
economic
Accordingly,
A across
controllable
controllable
simple the the
dual compressor
design
design
columnended results
results
pressure suction
indicate
decentralizedand throttling
that when
that
necessary when
composition avalvefixedfor
fixed
compression
control sufficient
speed
speed drive
drive
ratio
system are
is
shown
compressor
rangeability to provide
is used,
towards effective
significant
worst-case column regulation.
pressure
disturbance drop The
must
rejection. economic
be provided
Accordingly, controllable
across the
thespeed design
column results
compressor
pressure indicate
suction that when
throttling
and necessary a
valvefixed
compression forspeed drive
sufficient
ratio are
compressor
showncompressor
higher for
to anis
provide used,
is used,
overall significant
significant
more
effective pressure
expensive
column pressure drop
process
regulation. drop must
must
compared
The bebe
economic provided
provided
to a across
across
variable
controllable the
the compressor
compressor
drive
design suction
compressor.
results indicate throttling
throttling
The
that case
when valve
valve
study
a forspeed
for sufficient
sufficient
highlights
fixed the
drive
compressor
rangeability
higher for an is used, significant
towards
overall worst-case
more pressure
expensive disturbance droprejection.
process must
compared be Accordingly,
provided
to stage
a variableacross
the the
column
speed compressor
drivepressure suction
and
compressor. throttling
necessary
The case valve highlights
compression
study for sufficient
ratio are
the
rangeability
rangeability
importance
compressor towards
for
is towards
considering
used, worst-case
worst-case
significant control disturbance
disturbance
at the
pressure droprejection.
conceptual rejection.
must be Accordingly,
design Accordingly,
provided for the
the column
column
designing
across the pressure
pressure
a robust
compressor and necessary
operable
suction necessary
process.
throttling compression
compression
valve highlights ratioare
for ratio
sufficient are
rangeability
higher for an towards
overall worst-case
more expensive disturbance process rejection.
compared Accordingly,
to a variable thespeed
column drivepressure and necessary
compressor. The case compression
study ratio the
are
importance
higher
higher
rangeability for for
an
for an
towardsconsidering
overall overall more more
worst-case control
expensive
expensiveat the
disturbance conceptual
process
process compared
compared
rejection. design to stage
to a
Accordingly, a for
variable
variabledesigning
speed
speed
thespeed
column a
driverobust
drive operable
compressor.
compressor.
pressure process.
The
The
and necessary case
case study
study highlights
highlights the
the
importance
higher
Keywords: for an for
C considering
3 overall
splitter, more
process control
expensive
design, at the conceptual
process
controllability, compared design
process to stage
a controlfor designing
variable a robust
drive operable
compressor. process.
The casecompression
study highlights ratio the
are
importance
importance
higher
Keywords: for for
an
C considering
for
overall
splitter,considering
more
process control
control
expensive
design, at at the conceptual
the
process conceptual
controllability, compared design
design
process to stage
a stage for
fordesigning
variable
control designing
speed aa robust
driverobust operable The
compressor. process.
process. case study highlights the
importance
Keywords: for
C 3 considering
splitter, process control
design, at the conceptual design
controllability, process stage for designing a robust operable process.
control
© 2020,
importance
Keywords:
Keywords: IFAC for
C 33 (International
Cconsidering
3 splitter,
3 splitter, process Federation
control
process design, at the
design, of controllability,
Automatic
conceptualControl)
controllability, designprocess
process Hosting
stage forby
control
control Elsevier aLtd.
designing All rights
robust operablereserved.
process.
Keywords: C3 splitter, process design, controllability, process control
Keywords: C3 splitter, 1. process
INTRODUCTION design, controllability, process control condenser (minor fraction) are collected in a reflux drum. Any
1. INTRODUCTION condenser
uncondensed (minor
vapour fraction)
is sentare collected
to thein a reflux drum. Any
High purity propylene 1. INTRODUCTION
(>99 mol%) is a very important condenser
1. INTRODUCTION condenser(minor (minor fraction)
fraction) areback
collected incompressor
aaareflux
refluxdrum.
drum.suction.
Any
1. INTRODUCTION uncondensed
condenser
The design vapour
(minor
and is sentare
fraction)
control are
of collected
back to thein
collected
vapour incompressor
reflux drum.
recompression Any
suction.
Any
based
High purity
feedstock for the propylene
downstream (>99 petrochemicals
1. INTRODUCTION mol%) is a very important
industry. In condenser
uncondensed
uncondensed (minor
vapour
vapour fraction)
is sentare
is sent collected
back
back to
to the
the incompressor
a reflux drum.
compressor Any
suction.
suction.
High High purity purity propylene
propylene (>99
1. INTRODUCTION (>99 mol%)mol%) is isa avery
very important
important The design
uncondensed
fractionation
condenser and
vapour
systems
(minor control
is
has
fraction) sent of
been
arebackvapourto
studied
collected the recompression
in
in compressor
the
a literature.
reflux drum. based
suction.
Most
Any
feedstock
High
addition to for
purity the
polypropylene, downstream
propylene (>99
it petrochemicals
mol%)
is apetrochemicals
raw material is a very
intoindustry.
important
the value In uncondensed
The design
The design vapour
and
design systems is
control
and control
control sent ofbackvapour
vapourto the compressor
recompression
recompression suction.
based
based
feedstock
High
feedstock for
purity forthe thedownstream
propylene downstream(>99 mol%) is a very
petrochemicals industry.
important
industry. InIn uncondensed
fractionation
The
of these studies and focus
vapour ishas
either
sentbeen
of
only
back studied
vapour
ontothe thein the literature.
recompression
design
compressor aspect suction.Most
orbased
only
addition
feedstock
chainHighof to to polypropylene,
for
products
purity the downstream
such
propylene it
as cumene,
(>99is a raw
mol%) material
petrochemicals
acrylonitrile,
is a very intoacrylic the
industry.
importantvalue
acid,In The design
fractionation
fractionation and
systems
systems control
has of
been vapour
studied
studied recompression
in
in the
the literature.
literature. based
Most
Most
addition
feedstock
addition polypropylene,
for the
to polypropylene, downstream it is
it isapetrochemicals
raw material
a acrylonitrile,
raw material into the
industry.
into thevalue
value of
on
The these
In fractionation
the studies
control
design andfocus
systems
aspect either
has
control and only
been
ofdovapouron the
studied
not indesign
address
recompression aspect
the literature.
the orbased
only
Most
interaction
chain
addition
propylene
feedstockof to products
polypropylene,
oxide,
for the such
epoxies, as isopropyl
downstream cumene,
it is apetrochemicals
raw material
alcohol etc. intoacrylic
In the
refineries,
industry. acid,
value In fractionation
of
ofthese
these studies
studiessystems
focus
focus has
either been
only
only studied
on
on the
the in the literature.
design
design aspect
aspect oror Most
only
only
chain
addition of
chain products
to polypropylene,
ofoxide,
products such such as cumene,
asit cumene,
is a raw acrylonitrile,
material
acrylonitrile, intoacrylic the value
acrylic acid, on
of the
these
acid, fractionation
between control
studies
design aspect
focus
and
systems control.
has and
either do
only
For
been not
on
example,
studied address
the design
Chang
indesign
the the the
aspectinteraction
or
etinteraction
al. or
literature. only
(2017)
Most
propylene
chain
the of
propylene
addition products
to is epoxies,
such
purified
polypropylene, asto isopropyl
cumene,
the desired
it isopropyl
is a raw alcohol
acrylonitrile,
extent
material etc.in In
a
into Crefineries,
acrylic the acid,
splitter.
value of
on
on these
the
the studies
control
control focus
aspect
aspect either
and do
only
do on
not
not the
address
address aspect
the only
interaction
chain
propyleneof
propylene products
oxide, oxide, such
epoxies, as
epoxies, cumene,
isopropyl acrylonitrile,
alcohol
alcohol etc.etc. acrylic
In 3refineries,
Inrefineries, acid, between
on the
synthesize
of these design
control and
aspect
and optimize
studies focus control.and For
do
a vapour
either only example,
not address
onrecompression
the Chang
design the et
aspect al.
Cal. (2017)
interaction
splitter
or only
the
It propylene
propylene
fractionates
chain ofpropyleneoxide,
products isa purified
epoxies,
mixed
such Cto the
isopropyl
stream
asto3isopropyl
cumene, desired alcoholextent
(propylene
acrylonitrile, etc.in+ a
In C
propane)
acrylic 3 splitter.
refineries, to
acid, betweenbetween
on the
between design
control
design and
aspect
and control.and
control. For
do example,
not
example, address Chang
Chang the et
et (2017)
3 (2017)
interaction
al.
the the
propylene
propylene oxide, is is purified
epoxies,
purified to
the the desired
desired alcohol extent
extent etc.in inIn
a aCrefineries,
C splitter.
3 3splitter.
3 synthesize
with
on theheat and
design
control optimize
and
recuperation
aspectcontrol. ato vapour
and For
demonstrate
do not recompression
example, address Chang
significant
the Cal.
3 splitter
etinteraction
(2017)
energy
splitter
It fractionates
the propylene
recover high isa purified
purity mixed Cto3isopropyl
propylene stream
the desired
as the (propylene
extentetc.
distillate in+Inapropane)
Crefineries,
3 splitter. synthesize
to between
synthesize and
design optimize
and andoptimize
control. a vapour
vapour
For recompression
recompression
example, Chang C
etC3al.
3splitter
(2017)
propylene
the
It It
propylene
fractionates oxide,
fractionates epoxies,
a mixed
isa purified
mixed Cto3 Cthe3 stream
stream desired alcoholextent in+product
(propylene
(propylene a+propane)
Cpropane) with
3 splitter. to with
to synthesize
savings.
between heatThe
designrecuperation
and optimize
controllability
and control. ato vapour
demonstrate
aspect
For isrecompression
example, however significant
Chang
3
Cal. energy
3 splitter
notetconsidered.
(2017)
recover
It fractionates
propane
the propylene high
and purity
a purified
some
is mixed Cto33 the
propylene
propylene stream asleaving
the
desired distillate
(propylene down
extent in product
+the
a propane)
C bottoms. with
splitter. to with
with heat
synthesizeheat recuperation
recuperation
and optimize ato vapour
demonstrate
demonstrate recompression significant
significant C 3 energy
energy
splitter
It recover
fractionates
recover high high a purity
purity mixed propylene
C3 stream
propylene as asthe thedistillate
(propylene distillate +the product
propane)
product 3 with
with savings.
with
to savings. heat
Similarly,
synthesize The Leo
andcontrollability
recuperation
et al. (2018)
optimize ato aspect
demonstrate
vapour isrecompression
optimize however an not considered.
significant energy
ethylene-ethane
C3 splitter
propane
recover
Propylene
It fractionates and
high some
purity
(boiling a mixed propylene
propylene
point: C3 -47.6
stream asleaving
the
°C) down
distillate
and
(propylene propane product
+the propane)bottoms.
(boilingwith savings.
with
to savings. heatThe
The controllability
controllability
recuperation to aspect
aspect
demonstrateis
is however
however not
not
significant considered.
considered.
energy
propane
recover
propane high
and and purity
some some propylene
propylene
propylene leaving
asleaving
the down
distillate
down thebottoms.
product bottoms.
with Similarly,
splitter
with The
with
heat Leo
vapouret
recuperation al.
controllability (2018)
to aspect
recompression optimize
demonstrateis
buthowever
doan an
not ethylene-ethane
not considered.
address
significant process
energy
Propylene
propane
point: -42 and (boiling
°C) some
are point:
closepropylene
boilers -47.6 °C)
leaving
with low and down propane
relative the (boiling
bottoms.
volatility. In Similarly,
Similarly,
savings. The Leo
Leo et al.
et al. (2018)
controllability aspect optimize
optimize
is however an ethylene-ethane
ethylene-ethane
not considered.
recover
Propylene
Propylene
propane high
and purity
(boiling
(boiling
some propylene
point:point:
propylene -47.6 as
-47.6 the
°C)
leaving °C) distillate
and and
down product
propane
propane the bottoms. with
(boiling
(boiling splitter
Similarly, with
controllability. vapour
Leo Atet recompression
al.
the (2018)
other end, but
optimize
Muhrer do not
an et address
al. (1990) process
ethylene-ethane have
point:
Propylene -42 °C) are
(boiling close
point: boilers -47.6 with °C) low and relative
propane volatility.
(boiling In savings.
splitter
splitter
Similarly, The
with
with Leocontrollability
vapour
vapouret recompression
al. (2018)aspect
recompression is
but
but
optimize however
do
do not
not
an not
address
addressconsidered.
process
process
ethylene-ethane
order
propane
point:
point:
Propylene to and
-42 avoid
-42
°C) areexpensive
some
°C)
(boiling are
closepropylene
close
point: refrigeration,
boilers
boilers -47.6 leaving
with with
°C) low low
and arelative
down conventional
relative
propane the bottoms.
volatility.
volatility.
(boiling CInIn controllability.
3 splitter withcontrol At
vapour the other
recompression end, Muhrer et al.
but doillustrative
not al. (1990)
address have
process
order
point: tomust
-42 avoid
°C) expensive
areoperated
close boilers refrigeration,
with lowand a(17-25
conventional
relative volatility. CInC devised
Similarly,
controllability.
3 controllability.
splitter Leo
withcontrol
vapouret
At
At the thestructures
al. (2018)
other
recompression
other end, for
optimize
Muhrer
end, Muhrer an
et
but doillustrative
not
et (1990)
address
al. (1990) vapour
ethylene-ethane have
process
have
splitter
Propylene
orderorder
point: -42 to to
avoid be
(boiling
avoid
°C)beareoperated point:
expensive
expensive
close boilers at high
-47.6 pressure
°C)
refrigeration,
refrigeration,
with a
low relative propane
aconventional bars)
conventional
volatility. for
(boiling C a devised
controllability.
Ina3 devised
3 At thestructures
other end, for
Muhrer et al. (1990) vapour
have
splitter
order to mustavoid expensive at high pressure
refrigeration, a (17-25
conventional bars) for C
3 recompression
splitter
devisedwithcontrol
controllability. vapour
control
Atdistillation
recompression
the structures
structures
other systems
end, but for
for
for
Muhrer do nota al.
illustrative
et given
address
illustrative (1990) design,
process
vapour
vapour
have
cheap
ordersplitter
point:
splitter -42
towater
must must
°C)
avoid becooled
arebe close
expensive
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at at high
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pressure further
low relative
a (17-25 reduces
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3
recompression control distillation
structures systems for for a
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vapour
cheap
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condenser.
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bars)
reduces relative
for the
Ca3 recompression
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systems et al.
for (2017)
a given apply MPC
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devised
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et al.
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indicating
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thea including the C3 splitter. Hinogosa
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relative
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et for
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relative
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more thus
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This
indicating columns
further
pressure,
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reduces refinery the
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with The
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volatility
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The C
C
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splitter
volatility.
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indicating
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a columns
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in a arefinery
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Compressor
3 splitter is thus one of the tallest columns aa refinery Compressor
with
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splitter
to 250trays
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high columns
reboiler duty.
duty. in refinery Compressor
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with ToC
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is
thus
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employ
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reduction
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tallest
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reboiler
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recompression energy
in
a refinery
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with To up achieve
to 3
250 a
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high in
reboiler theduty.energy budget,
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with modern
To up heat
toC250
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asplitters
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most
highvapour
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inrecompression
commonly
reboiler theduty.energy
employed (VRC)
(VRC)
budget, C Column
modern
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achieve 3
3 splitters
aintegration. employ
significant vapour
reduction recompression
in the energy (VRC)
budget, 3
Column
Column Distillate
basedbased
modern
splitter
To heat Cheat
VRC
achieve 3 integration.
splitters
flowsheet
a employ
significant The The most
arrangement mostcommonly
vapour
reduction commonly
recompression
is
in shown
the energy employed
employedin (VRC)
Fig.
budget, C1C3 3 Column Distillate
Distillate
modern
based heat
splitter
splitter C
VRC splitters
integration. employThe vapour
most
3 VRC flowsheet arrangement is shown in Fig. 31
flowsheet arrangement recompression
commonly
is shown employedinfrom (VRC)
Fig. C 3 Column Distillate
based
(Annakou
modern heat C3and integration.
Mizsey,
splitters The
1995).
employ most
The
vapour commonly
overhead employed
vapour
recompression (VRC) C13
the Column
Distillate
Distillate
based
splitter heat
(Annakou
(Annakou VRC integration.
and flowsheet
Mizsey, The1995). most
arrangement The commonly
is
overhead shown employed
vapour in Fig.
from C 1
the3 Distillate
splitter
column
based
splitter
(Annakou heat isand
VRC
VRC and
Mizsey,
flowsheet1995).
compressed
integration.
flowsheet
Mizsey, The
1995).to The
arrangement
amost
arrangement
The
overhead
pressure is where
commonly
overhead is
vapour
shown
shown employed
vapour
infrom
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in from
Fig.
bubble
Fig.
the
C1
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(Annakou
temperature is and is compressed
compressed
Mizsey,
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condensing where
wherevapour its its
from
compressed bubble
bubblethe Feed
splitter
(Annakou
column VRC
is and flowsheet
compressed 1995).arrangement
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shown
vapour infrom
its Fig.
bubblethe 1 Feed
Feed
temperature
temperature
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high enough
enough to for for thecondensing
theoverhead condensingcompressed compressed
vapour
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and compressed reboiler
Mizsey, heat
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temperature
vapour
vapour
temperature to tocompressed
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compressed
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a condensation
pressure
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forthethe The where
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the the
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to be the issuch such
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on
compressed
temperature
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isthe
is high such isenough
reboiler
vapour
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the
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source.
higher The than
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balance
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on
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compressed
the column
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vapour to bevapour is such
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vapour
source. than energy
condensation
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split into
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compressed
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that
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condensation
vapour stream the reboiler
duty
split ofduty.
into the
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compressed
with
the withthe
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vapour compressed
fraction
is such is slightly
condensing vapour
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the higher in stream
than
the
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reboiler split
reboiler
dutyto to into
providetwo
duty.
ofprovide
the
compressed
Accordingly,
with vapour
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major the is
compressed
fractionslightly higher
vapour than
stream
in thethe is reboiler
split
reboiler into duty.
two
Accordingly,
vapour thefraction
compressed
into is the condensing vapour inThethe minor
stream reboiler
is reboiler
split tointoprovidetwo
compressed
Accordingly,
with vapour
the major vapour
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boilup compressed
into thecolumn.
slightly
condensing higher
vapour
column. in than
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cooled minor and fraction
condenser. the auxiliary The is Bottom
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fraction The is Fig.
Fig. 1.
1. Schematicof
Schematicof VRC
VRC CC 3
splitter
3 splitter processprocess
Bottom
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from reboiler water fraction)
(major cooled and condenser.
the auxiliaryThe Fig. 1. Schematicof VRC C3 splitter process Bottom
condensate
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in an the reboiler (major fraction) and the auxiliary
2405-8963
condensate © 2020,
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reboiler waterFederation
(major cooled ofand
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ElsevierSchematicof
Ltd. All VRC
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reserved.
Fig. 1. Schematicof VRC C3 splitter process 3 splitter process
3 Bottom
condensate
Peer review under fromresponsibility
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International and theofauxiliary
Federation Automatic Control. Fig. 1. Schematicof VRC C3 splitter process
10.1016/j.ifacol.2020.06.020 Fig. 1. Schematicof VRC C3 splitter process
118 Aditya Anand et al. / IFAC PapersOnLine 53-1 (2020) 117–122
and real time optimization to a VRC based C3 splitter at
Petrobras, Brazil, i.e. on a VRC C3 splitter with a given
design. In both cases, how are the nominal designs obtained is
not clarified. Other researchers have also looked exclusively
at either the design aspect or the control aspect of vapour
recompression distillation systems (Jogwar and Daoutidis,
2009; Jana, 2014). This suggests the need for systematically
evaluating both economic design and control of vapour
recompression based distillation systems.
It is well established that control considerations typically
necessitate process overdesign so that the expected worst-case
disturbance is effectively rejected (Fisher et al., 1985). One
therefore seeks the cheapest equipment overdesign that allows
effective rejection of the expected worst-case disturbance
(Sandoval et al., 2011). From the control perspective, the
control degree of freedom (dof) associated with the
compressor is particularly important since the compression
provides the necessary temperature driving force for heat
integration in the reboiler. Usually a centrifugal compressor is
used for VRC in a C3 splitter. The compressor may be of the
fixed speed type or the variable speed type, the former being
cheaper and more common. Fixed speed compressors,
typically have suction valve throttling as the associated
control dof. Variable speed compressors, on the other hand,
have compressor speed as the associated control dof. For a
fixed speed compressor with suction valve throttling, the
column pressure must necessarily be higher than the suction
pressure due to pressure drop across the suction throttling
valve. Further, this pressure drop must be large enough to
ensure good rangeability for rejecting expected disturbances.
The larger the resistance of the throttling valve, the larger the
pressure drop and the larger the rangeability. This benefit
however comes at the cost of a larger compressor as well as
lower relative volatility, since the column must operate at a
higher pressure due to the pressure drop across the suction
valve. Clearly, the design-control interaction for a VRC C3
splitter is intimately tied to the compressor type and
associated control dof. To the best of our knowledge, the issue
has not been addressed in the extant literature and is
specifically addressed the here.
In the following, a steady state economic process design is
developed followed by controllability evaluation of the
designs using rigorous dynamic simulations to finalize the
recommended designs for fixed speed and variable speed
compressors. The article ends with a summary of the main
findings from the work.
2. PROCESS MODEL
Aspen Hysys (V8.8) is used for steady state and dynamic
process modelling. Since the system is a binary hydrocarbon
mixture, the Peng Robinson equation of state is used for
thermodynamic property modelling. To assess the suitability
of the vapour-liquid-equilibrium (VLE) predictions, Fig. 2,
overlays experimental data points (Hanson et al., 1952) on the
model predicted x vs y equilibrium curve at 22.24 bar. The
predictions are in good agreement with the experimental data,
thus validating the model.
3. STEADY STATE ECONOMIC PROCESS DESIGN
The VRC C3 splitter is to be designed for both a fixed speed
compressor and a variable speed compressor configuration.
Fig. 2. Predicted x-y curve with experimental points
The system is to process 100 kmol/h of a binary propylene-
propane feed with a nominal propylene mol fraction of 60%.
The feed comes in as a liquid from a pressurized tank at 30
°C. The desired distillate purity is 99 mol% propylene while
the desired bottoms propylene impurity is 3 mol%, so that the
propylene loss in the bottoms is small. To account for
controllability considerations at the design stage, the process
is to be designed for effective rejection of the worst-case
disturbance. The worst-case disturbance direction is the one
that requires the compressor suction valve opening
(compressor duty) to increase when a fixed (variable) speed
compressor is used. A simultaneous 10% increase in the feed
rate and a 10 mol% increase in the feed propylene mol
fraction is taken as the worst-case disturbance.
3.1 Steady state process simulation
The principal design variables are the number of trays in
the tower (N), the feed location (NF), the tower operating
pressure (P), the compression ratio (CR) and the compressor
suction throttling valve pressure drop (ΔP). Note that a
variable speed drive compressor will not have a suction
throttling valve so that ΔP in that case is 0 bar.
The short-cut Fenske-Underwood-Gilliland method
(Fenske, 1932; Underwood, 1949; Gilliland, 1940) is
appropriate for column design. Accordingly, the total # of
trays (N) and feed tray location (NF) is taken as that calculated
from the short-cut method for the nominal feed conditions and
a reflux ratio that is 1.25 times the minimum reflux ratio. The
calculation is done for the nominal feed condition. With N and
NF thus fixed, a rigorous steady state simulation of the VRC
C3 splitter can be performed in Hysys. For robust steady state
flow sheet convergence, the specific flowsheet in Fig.1 is built
as a reboiled column with a bottoms product and an overhead
vapor product. The tray section top pressure (P) is fixed at the
desired value and the bottom tray pressure is fixed assuming a
0.5 kPa pressure drop per tray. The compressor suction valve
pressure drop is specified to the desired value (ΔP). The
compressor outlet stream pressure is fixed by the compression
ratio (CR). On the reboiled column, the bottom propylene
impurity is specified as 3 mol%. A converged column directly
gives the reboiler duty (Qreb) for the specified bottoms
impurity. Since Qreb comes from condensing the major
fraction of the compressed overhead vapour split stream, a
spreadsheet is used to import the calculated Qreb and the duty
of the cooler on the major compressed vapour split stream
(Qc2). An adjuster block adjusts the vapour split to drive the
difference between the two (Qreb – Qc2) to zero. The exact
 Aditya Anand et al. / IFAC PapersOnLine 53-1 (2020) 117–122 119
value of the vapour split for closing the heat integrated
column energy balance is thus obtained. This leaves only the
reflux-distillate split fraction as the remaining specification,
which is adjusted for a distillate propylene purity of 99 mol%.
The steady state flowsheet is thus converged to achieve the
desired product purities for the specified P, ΔP and CR.
3.2 Economic objective
To obtain an economic steady state design, an objective
function combining the operating cost and the equipment
capital cost is needed. Since the equipment is to be
appropriately oversized for worst-case disturbance rejection,
the capital cost must be for the oversized equipment
corresponding to the steady state material and energy flows
for the worst-case disturbance. On the other hand, the
operating cost should be for the nominal steady state as the
process is expected to operate around the nominal steady state
most of the time, with infrequent disturbances. The total
annualized cost (TAC) is defined here as
TAC = Oversized Equipment Capital Cost/PBP + Yearly
Operating Cost
where PBP is the payback period. A PBP of 3 yrs is used here
(Kayode, 2010). The equipment cost correlations and
operating costs used here have been adapted from Turton et al.
(2011). A pressure correction factor is used in the tower cost
as the tower is expected to operate at moderate pressures (5-25
bars). The compressor assembly consists of an electric drive
and a centrifugal compressor unit. Since variable speed drives
are significantly more expensive, the variable speed drive cost
is taken to be 2 times the fixed speed drive cost.
The equipment is oversized corresponding to the material
and energy flows for the worst-case disturbance. Thus, the
column diameter is chosen as corresponding to 80% vapour
flooding velocity at the worst-case feed condition. Similarly,
the reboiler and condenser heat transfer areas are oversized to
25% above the worst-case energy flows. Conservative heat
transfer coefficient values of 800 and 400 W m-2 °C-1 are used,
respectively, for the reboiler and the condenser (Couper et al.,
2010). The compressor duty is oversized by 25% above the
duty for the worst-case disturbance. The 25% extra oversizing
above the worst-case disturbance is to hedge against
uncertainties that have not be modelled for, such as fouling of
trays and heat transfer tubes, valve degradation etc.
3.3 Design procedure
The dominant design variables are the column pressure (P),
the compressor suction valve pressure drop (ΔP; ΔP = 0 for a
variable speed compressor) and the compression ratio (CR).
Column pressure is important as it affects relative volatility.
Sufficient ΔP is needed in fixed speed compressor designs to
ensure good controllability. It however causes the column
pressure to be higher, adversely affecting relative volatility.
Also, the CR is then higher to ensure sufficient heat transfer
temperature driving force in the reboiler. CR itself is
important as it determines the compressor cost as well as
wattage, both being major contributors to the TAC. We wish
to obtain reasonable values for P, ΔP and CR for an economic
controllable design with single stage compression. This is Each of the candidate designs in Table 1 is evaluated for
done as follows.
Single stage compression implies that CR is constrained to be
below 3 (Boyce, 2011). At a given P and ΔP, CR fixes the
compressed overhead vapour stream pressure, which in turn
fixes its bubble temperature. In order to use cooling water as
the coolant in the auxiliary condenser, this bubble temperature
must be at least 50 °C and not lower for sufficient temperature
difference to drive heat transfer in the condenser. Further the
compressed overhead vapour bubble temperature must be at
least 15 °C above the reboiler temperature to drive reboiler
heat transfer. Designs that do not satisfy any of these two
constraints are deemed infeasible. The simple step-by-step
design procedure noted below is used here:
1. Choose compressor suction throttling valve pressure drop,
ΔP (candidate values: 0, 1, 3, 5 and 7 bars)
2. Fix column top pressure, P (candidate values: 5, 7, 9, 11,
13, 15, 17, 19 and 21 bars)
3. Fix N and NF to shortcut method values for nominal feed
4. Specify column pressure drop such that per tray pressure
drop is ~0.5 kPa
5. Repeat steps 6 to 9 for different values of compression
ratio, CR
6. Converge process for nominal feed condition and obtain
nominal operating cost
7. Converge process for worst-case feed condition. Oversize
equipment based on worst-case material and energy flows
8. Calculate TAC using nominal operating cost and
oversized equipment capital cost for worst-case
disturbance steady state.
9. Check if sufficient temperature driving force for heat
transfer exists in condenser and reboiler. If yes, the design
is deemed feasible; if no, it is deemed infeasible.
10. From the various designs, shortlist the lowest TAC
feasible design at a given ΔP as one meriting further
control evaluation.
Fig. 3 plots the variation in TAC with CR at each of the ΔP
values for different column pressures. The solution points for
which sufficient temperature driving force is not available to
drive the auxiliary condenser or reboiler are clearly indicated
as infeasible in the Figure (dashed lines). The P and CR values
for the least expensive feasible design are thus obtained for
each ΔP using steady state analyses.
In Fig. 3, note that at low CR, the process is infeasible due
to insufficient temperature driving force in the reboiler. This is
expected as unless the overhead vapour is sufficiently
compressed, using it as the source of heat in the reboiler is not
possible. Also, as the ΔP is increased, the column pressure for
which the maximum allowed CR of 3.0 achieves the minimum
temperature driving force in the reboiler increases. The salient
design parameters for the cheapest feasible design for each of
the considered ΔP values are noted in Table 1. Furthermore,
note that the TAC for the cheapest design at ΔP = 0 is more
than for the cheapest design for ΔP = 1 bar. This is because
the ΔP = 0 design requires a variable speed drive, which is
much more expensive than the fixed speed drive implied for
non-zero ΔP designs.
4. CONTROLLABILITY EVALUATION
worst-case disturbance rejection using rigorous closed loop
dynamic simulations. The cheapest design that effectively
120 Aditya Anand et al. / IFAC PapersOnLine 53-1 (2020) 117–122

rejects the worst-case disturbance would be finally the feed rate under flow control. The valve on the minor
recommended. For a realistic dynamic simulation, the reboiled compressed vapour split stream is manipulated to hold the
column in the steady state simulation is replaced with a simple compressor outlet stream pressure. This closes the column
tray section and a process-to-process heat exchanger that energy balance by adjusting the vapor split such that the
generates the vapour boilup into the column by condensing energy needed in the column reboiler comes via condensation
the major fraction of the compressed overhead vapour. The of the major compressed vapor split fraction. In dynamics, if
reflux drum and bottom sump are sized for a 5-10 min the energy balance is not closed, the pressure in the vapor loop
residence time at 50% holdup for the nominal steady state. will drift. This change in pressure is used as an indicator for
The column diameter is set for a superficial vapor velocity of appropriately adjusting the vapor split. With proper closure of
80% flooding velocity for the worst-case disturbance. the column energy balance, the rest of the control system is
straightforward. The reflux rate is maintained in ratio with the
distillate and the reflux drum level is maintained by
manipulating the distillate rate. The bottoms rate is
manipulated to hold the sump level. For the fixed (variable)
speed compressor system, a bottoms propylene impurity
controller manipulates the compressor suction valve position
(compressor duty). The top product purity is maintained by
adjusting the reflux ratio setpoint.
The two level controllers are P only and use a proportional
gain of 2 (%/%). The feed flow controller is PI with a
proportional gain of 0.5 and reset time of 1 min. The flow
span is twice the nominal steady flow. The compressor outlet
stream pressure controller is tuned using the Hysys autotuner
with Zeigler Nichols settings. The two composition controllers
are tuned sequentially via hit-and-trial for a smooth closed
loop dynamic response. Since the distillate is the product
--------- Infeasible stream, tight distillate purity control is prioritized over
* * * * * Feasible bottoms impurity control. Accordingly, a PI distillate purity
controller is first tightly tuned for a somewhat oscillatory
servo response with the bottoms impurity controller on
Fig. 3. Variation in TAC with CR and ∆P manual. Then the PI bottoms impurity controller is tuned with
the distillate impurity controller on automatic. Since it is the
bottoms impurity controller that manipulates the compressor
Table 1. Cheapest TAC designs at different ΔP dof, the controller gain and reset time are chosen to be not too
ΔP Col Pressure # of Feed Qcmp TAC ($
aggressive. This is done to ensure that for disturbances that
CR cause the compressor control valve to open, the valve opening
(bar) (bar) Trays (N) Location (NF) (kW) 105 yr-1)
moves smoothly to the final steady state without a large
0 11.7 121 86 1.765 1281 7.84
overshoot so that further equipment oversizing to
1 13 121 86 1.883 1506 7.48
accommodate the overshoot is not required.
3 15 128 91 2.136 1819 8.61
The bottleneck constraint that limits controllability is the
5 17 134 74 2.385 2253 9.83
7 19 144 102 2.634 2792 11.0
saturation of the control dof associated with the compressor.
Thus, for the fixed speed compressor type, the compressor
suction valve opens fully while for the variable speed drive
Fig. 4 shows the control structure for the fixed speed and compressor, the compressor duty reaches maximum. Fig. 5
variable speed VRC C3 splitter column. Two temperature plots the response of the compressor control dof for the two
controllers (TCs) are shown in black that pull in the compressor types. The top and bottoms composition responses
appropriate amount of process fluid into the cold side and the are also plotted. Notice that for designs with ΔP= 1 and 3 bars,
hot side, respectively, of the reboiler to mimic the the compressor suction valve saturates for the worst-case
thermosiphon self-regulatory mechanism. TC on the cold side disturbance and the final bottoms propylene impurity is 15.83
manipulates the flow rate of liquid pulled in from the sump mol% and 4.03 mol% respectively, which is higher than the
into the reboiler to hold the boilup temperature at a value desired 3 mol% target. This off-target steady state loss of
slightly above the saturated vapour temperature (slight propylene in the bottoms stream for the worst-case
superheat). Similarly, TC on the hot side manipulates the flow disturbance is unacceptable and the designs are rejected due to
rate of the compressed vapour into the reboiler to hold the poor control performance. On the other hand, for both the 5
condensate temperature at a value slightly below the saturated and 7 bar ΔP designs, the worst-case disturbance is effectively
liquid temperature (slight subcooling). These two controllers rejected without the suction valve saturating and the final
are tuned tightly to emulate the extant self-regulatory steady state bottoms propylene impurity settles at the target of
mechanisms of reboiler and should be viewed as part of 3 mol%. Both these designs are thus acceptable from the
process and not external controllers implemented in a DCS. control perspective. Since the 5 bar ΔP design is 16.24%
The DCS decentralized control loops are now described. cheaper than the 7 bar ΔP design (see Table 1), the former is
Dual-ended composition control is applied to the column with
 Aditya Anand et al. / IFAC PapersOnLine 53-1 (2020) 117–122 121

recommended as the cheapest fixed speed compressor design Table 2. Economic data for recommended process designs
that effectively handles the worst-case disturbance.
Design and Economic Details ΔP 0bar* ΔP 5bar#
For the variable speed compressor type, the oversizing of
the compressor above the worst-case disturbance rejection Pressure (bar) 11.7 17
requirement allows for effective worst-case disturbance # of Trays (N) 121 134
Column
rejection without any valve saturation or violation of the Feed location (NF) 86 95
column flooding limit. This may be verified from the transient Capital cost ($ 106) 0.248 0.259
response in Fig. 5. The cheapest ΔP = 0 bar design in Table 1 Duty (kW) 565 1229
is therefore the recommended design for the variable speed Compressor Capital cost ($ 106) 1.02 1.04
compressor type. Operating cost ($ 106) 0.176 0.352
Area (m2) 524 556
Reboiler
Capital cost ($ 106) 0.436 0.469
TAC ($ 106 yr-1) 0.784 0.983
*: Variable speed compressor; #: fixed speed compressor

For comparison purposes, we also obtained the TAC where the

capital cost is calculated based on the nominal steady state and
not the worst-case steady state. We found the TAC of the
nominal design was only ~2% lower than the corresponding
designs reported in Table 1. This suggests that the robust
controllability via overdesign comes at a minor incremental
cost. The overdesign is thus highly recommended.
Fixed speed compressor drive Variable speed compressor drive

Fixed speed compressor drive

Variable speed compressor drive ΔP=1 bar dotted

ΔP=3 bar dash dot ΔP=0 bar solid
ΔP=5 bar dashed
Fig. 4. DCS for VRC C3 splitter ΔP=7 bar solid

Table 2 reports the salient design and economic details of the
recommended controllable designs for the fixed and variable
speed compressor types. Overall, the variable speed
compressor type design, with a TAC of $0.784x106, is
significantly less expensive than the recommended fixed
speed compressor type design with a TAC of $0.983x106,
which is a substantial ~25% higher. This is because in the
latter, controllability considerations require a larger pressure
drop across the compressor suction valve. This causes the
column pressure and compression ratio to be larger in order to
satisfy the minimum reboiler temperature driving force
constraint. Based on the results, the variable speed compressor
design is recommended for the VRC C3 splitter.
Fig 5. Transient response for worst-case disturbance
In practice, the worst-case disturbance is likely to be very
infrequent and one expects smaller deviations in the feed rate
and composition around the nominal values. It should
therefore be possible to make the bottoms impurity controller
more aggressive for tighter bottoms impurity control. The
aggressive tuning thus allows effective rejection of small
magnitude disturbances with tight distillate and bottoms
composition control. The closed loop dynamic response of
salient process variables using aggressive tuning for a ±10%
feed rate step change or a ±10mol% feed composition step
change are shown for the recommended variable speed or
122 Aditya Anand et al. / IFAC PapersOnLine 53-1 (2020) 117–122

fixed speed compressor process designs in Fig. 6. The Ind. Eng. Chem. Process Des. 24, 593-598.
aggressive control significantly improves the tightness of Gilliland, E.R. (1940). Multicomponent rectification. Ind.
distillate and bottoms purity control. Eng. Chem. 32, 1220-1223.
5. CONCLUSIONS Hanson, G.H., R.J. Hogan, W.T. Nelson and M.R. Cines
(1952). Propane-propylene system. Ind. Eng. Chem. 44,
In conclusion, this work has demonstrated the importance 604-609.
of controllability considerations at the design stage on the
Hinogosa, A.I., A. Ferramosca, A.H. Gonzalez and D. Odloak
design of a propylene-propane VRC splitter. A simple dual-
(2017). One-layer gradient-based MPC + RTO of a
ended decentralized composition control structure is shown to
propylene/propane splitter. Comp. Chem. Eng. 106, 160–
provide robust process stabilization. Overall, for the specific
170.
case study, the VRC C3 process design using a variable speed
compressor is found to be substantially (>20%) cheaper than Jana, A.K. (2014). Advances in heat pump assisted distillation
the corresponding design using a fixed speed compressor and column: A review. Energy Convers. Manag. 77, 287–297.
is therefore recommended. The equipment overdesign for Jogwar, S.S. and P. Daoutidis (2009). Dynamics and control
robust operability, as done here is strongly recommended as of vapor recompression distillation. J. Process Contr. 19,
the TAC is only 2-3% higher than the standard process design 1737–1750.
for the nominal steady state. Leo, M.B., A. Dutta and S. Farooq (2018). Process synthesis
and optimization of heat pump assisted distillation for
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(a) (b) (a) (b)

Variable speed compressor design Fixed speed compressor design

Aggressively Tuned: +10% throughput solid line Aggressively Tuned: +10% feed comp solid line
-10% throughput dashed line -10% feed comp dashed line
Loosely Tuned: +10% throughput dashed dot line Loosely Tuned: +10% feed comp dashed dot line
-10% throughput dotted line
-10% feed comp dotted line

Fig. 6. Transient response with aggressive/loose tuning bottoms impurity controller

(a) ±10% throughput change (b) ±10 mol% feed composition change