ict 1 rigorous simulation of divided- wall columns m. shamsuzzoha, maryam ghadrdan, ivar j....
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1ICT
Rigorous Simulation of Divided-wall Columns
M. Shamsuzzoha, Maryam Ghadrdan, Ivar J. Halvorsen, Sigurd Skogestad
The 15th NPCW'09, Telemark University College, Porsgrunn, Norway January 29-30 2009
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2ICT
Trondheim, Norway
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3ICT
NTNU/SINTEFTrondheim
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4ICT
Minimum Energy for the Four-Product Kaibel Distillation Column
IntroductionWhat is Petlyuk columnsExperimental setup Assessment by the Vmin diagram
Rigorous simulation Summary
ABCD
A
B
D
C
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5ICT
BEEDIST (Basic Energy Efficient Distillation Technology)
Founded by the Norwegian Research Council through the GASSMAKS program
SINTEF/NTNU 2008-2012 Objectives
Study new integrated distillation arrangements
For reduction of capital cost and energy consumption (+ CO2-emission related to the energy).
20-40% savings in reach. Evaluate application in natural gas
processing and conversion. Design and operation Develop laboratory 2 PhD + post doc
ABCD
CD
A
B
D
C
AB
NTNU lab4-product Kaibel-
column with a dividing wall
ABC
A
B
C
AB
BC
3-product Petlyuk arrangement
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6ICT
What is a Petlyuk arrengement ?
Integrated distillation column arrangement Separates a single feed into three separate
products Just a single reboiler and condenser
Why? Saves energy and capital Distillation consumes 3-5% of the industry
energy consumption world-wide
=>Need more energy efficient solutions
ABC
A
B
C
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7ICT
Industrial DWC/Petlyuk applications
German-speaking community dominates BASF: 40 DWCs in operation. Increasing. G. Kaibel pioner Monz – main vendor for BASF Krupp-Uhde Sulzer Rashig Linde
Others MW Kellogg (UK) UOP (USA) UK, Japan, Indonesia, South Africa
The Kaibel-column 4-product DWC!
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8ICT
Equivalent Petlyuk arrangements
Classical Petlyuk arrangement
Dividing Wall Column (DWC)
ABC
A
B
C
AB
BC
ABC
BC
A
B
C
AB Liquid split
Vapor split
Fully thermally coupled sections
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9ICT
Conventional alternatives for 3-product separation: Sequence of binary columns
ABC
BC
A B
C
Direct Split: DS
ABC
AB
A
BC
Indirect split: IS
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10ICT
ABC
BD
A
AB
B
C
B
Prefractionator arrangement
Alternatives for 3-product separation...
The prefractionator does the simple A/C
split while B distributes to both
ends
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11ICT
Conventional Prefractionator arrangementwith a single main column
ABC
BC
A
AB
B
C
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12ICT
Apply full thermal coupling
ABC B
C
A
AB
B
C
Petlyuk column
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13ICT
Why consider a Petlyuk arrangement Large potential energy savings compared to conventional
columns (20-30%) Or – increase production for given energy supply
Capital cost savings due to more compact equipment => smaller footprint and removal of reboiler/condenser units
Usage: In theory: Anywhere (almost) where distillation is a suitable
separation technology and more than 2 products are produced. In practice: Some cases may be unsuitable due to required
temperature/pressure range, height, or if liquid/vapor load in different sections are very different.
Practical variations can be made, e.g. side-strippers/rectifiers Revamping of existing conventional columns may have significant
potential
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14ICT
Critical: How to set the splits The potential savings are easily lost unless the splits are
adjusted properly Do it right and obtain all the benefits!
ABC
A
B
C
ABC
A
B
C
vapor split (Rv)
vapor split (side draw)
liquid split (side draw) liquid split
(Rl)D1
V1
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15ICT
Extend to 4-product DWC:The Kaibel column – (1987)
ABCD
CD
A
B
D
C
AB
Total reflux section
Separates 4 products in a single shell!
Can save 30-40 %
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16ICT
Minimum energy-Definitions and assumptions
Vapour flow rate (V) generated from all reboilers is used as the energy measure
Ideal Assumptions Infinite number of stages Constant relative volatility Constant molar flow Constant pressure No internal heat exchange
Then, exact analytic solution is obtained
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17ICT
Minimum energy (Vapor flow rate V)
Sharp splits: Flat optimum at a line segment (optimality region)
Optimality region depends on feed properties
Rapid increased vapor flow outside optimality region
( , , )minV f Splits Feed Specs
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18ICT
The Vmin-diagram
ABC
Distillate (D)
Feed (F)
Vapor rate (V)
D/F
V/F
1
Operation point f(D/F,V/F)
Two degrees of freedom – choose D/F,V/F
Binary column –multicomponent feed
Feed comp. distribution ? Minimum energy ?
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19ICT
The Vmin-diagram – 3 component example
D/F
V/F
Vmin
boundary
ABC
D
F
V
Preferred A/C split
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20ICT
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21ICT
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22ICT
zA:
zB:
zC:
A:
B:
qf:
Conventional : Vmin
=2.03Petlyuk Column: V
min=1.37
Reboiler SAVINGS: 32.80%Condenser SAVINGS: 32.80%
C 0.2 0.4 0.6 0.8 A
0.2
0.4
0.6
0.8
B
0 0.2 0.4 0.6 0.8 10
0.5
1
1.5
2
D/F
VT/F
P
R
Savings
0 0.2 0.4 0.6 0.8 10
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
C3
C2
V(Rl,R
v)
Rl
RC4
P
C1
Rv
Characterisitcs of operation
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23ICT
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24ICT
Schematic diagram of the experimental setup of 4-product Kaibel-arrangement
T50
6
2
1
3
T34
T66
VB
Rv
L/D
Rl
S1
S2
F, Z_F, q
x, B
D, x, d
x, S1
x, S2
TS-7
TS-1
TS-2
TS-3
TS-4
TS-5
5
7
4
TS-6
TEE101
TEE100
T34
ABCD
A
B
D
C
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25ICT
The Kaibel column at NTNU, Trondheim, Norway
Lab installation: Height: 8 meters Atmospheric pressure Vacuum glass sections 4 products Contact: Sigurd Skogestad, or
Ivar J. Halvorsen
A
B
C
D
Feed (ABCD)
ABCD
CD
A
B
D
C
AB
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26ICT
Feed condition for the Kaibel Distillation
Four components: Methanol+Ethanol+1-Propanol+1-Butanol
Flow rate F=1.0 Kgmole/h, q=1 (saturated liquid) Composition z=[0.25, 0.25, 0.25, 0.25] EOS Wilson Pressure Atmospheric Relative volatility α= [8.27: 4.84: 2.30: 1.0]
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27ICT
UniSim Simulation for Kaibel Column
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28ICT
Steady-State Simulation for Kaibel Column
KAIBEL DISTILLATION COLUMN
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29ICT
Minimum Energy – competition
No Configuration Ideal Vmin/F IdealSavings
UniSimSavings
1 Four product extended Petlyuk 1.16 51%
2 Kaibel column 1.59 33% >26%
3 Prefractionator+single main column
1.98 16%
4 Conventional direct sequence (3 columns)
2.38 0%(reference)
0%(reference
)
5 Prefractionator+2 separate columns
2.62 -10%(loss)
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30ICT
Vmin-diagram for the Kaibel column
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 10
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
D/F
V/F
Vmin
-diagram
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31ICT
Vmin-diagram for the Kaibel column using UniSim
Rigorous calculation confirms ideal shortcut method
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 10
0.2
0.4
0.6
0.8
1
1.2
1.4
V/F
D/F
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32ICT
Further work
Status: Startup of new PhDs Directions:
Further studies with Unisim (extended from ideal mixtures)
Further development of Matlab models Alternative structures like HIDiC, Heat integrated
and other energy efficient arrangements Dynamic studies Optimizing control Lab column experiments
ABCD
CD
A
B
D
C
AB
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33ICT
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34ICT
How to apply DWC/Petlyuk columns
Make sure to do a reasonable design in terms of placement of the dividing wall/design split.
Important: Make sure to indentify the optimality region for the expected actual feed variations, and thereby clarify the requirements for on-line adjustment of:1. None of the split ratios (E.g. in case of quadrangle shaped reg.)
2. Just the liquid split (In case of a line segment reg.)
3. Both split ratios (in case of a very short line segment)
Determine the final control strategy based the actual product value/energy cost, and dynamic controllability analysis.
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35ICT
Key issues for full thermal coupling
Liquid and vapour flows in equilibrium avoids irreversible loss due to mixing (Petlyuk 1965) => Explains why Petlyuk columns beat the other arrangements Require operation of every internal column at its “preferred split”
Underwood roots “carry over” the coupling (Halvorsen 2001) => Valid for any operating point Simple sequential calculation sequence Extremely simple assessment for n-product Petlyuk arrangement
based only on feed properties.