1

Process Integration Applied to the Design and Operation of Distillation Columns

Hilde K. Engelien

22. March 2004

Department of Chemical Engineering, NTNU

2

Introduction & Overview

• Process integration - definition• Motivation• Background

Overview of talk:• Introduction to multi-effect arrangements• Minimum vapour flowrate considerations

– Vmin as a target– Vmin-diagrams

• Multi-effect in practice– selecting controlled variables– industrial example

• Main contributions• Concluding remarks

3

Introduction

• Process Integration - definition

“Systematic and general methods for design (and operation) of integrated process plants, focusing on efficient energy use and reduced environmental consequences”.

International Energy Agency (IEA), 1993

4

Introduction

• Process Integration - definition• Motivation - energy savings, environment, innovation,...

• Distillation is a very common separation process:– performs about 95% of fluid separations in the chemical industries.

• Distillation is a very energy consuming process:– uses about 3% of the world total energy consumption.– accounts for around 25-40 % of energy usage in chemical and petroleum industry.

• Process integration – saves energy and reduces the environmental impact of a process

– reduce site utility costs (e.g. steam, cooling water)– may reduce capital costs

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Introduction

• Process Integration - definition• Motivation - energy savings, environment, innovation,…• Background to heat-integrated distillation columns

• Multi-effect prefractionator arrangements have high energy savings - is therefore an interesting arrangement to study.

• Operation of energy-integrated systems can be more difficult - want to operate so that the energy savings are achieved.

• Not many publications on the control of the integrated prefractionator/sidestream columns [Cheng & Luyben, 1985, Ding & Luyben, 1990, Bildea & Dimian, 1999, Emtir et al., 2003]

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Multi-Effect Distillation

= where pressure is used to adjust the temperature levels in two (or more) columns so that the condensing duty of one column can be used to provide heat in the reboiler of another column.

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A B C

A B

C

B C

Different Distillation Arrangements

Direct split (DS) Indirect split (IS)

A B C

A

BC

A BHP LP

forward-integration (F)

backward-integration (B)

LP HP

B

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Different Distillation Arrangements

Prefractionator columns

A B C

A

B

C

A B

B C

• 30 % less energy• prevents re-mixing effect of

middle component• Further energy savings can be

made with multi-effect integration.

Thermally coupled columns:• Single column shell (divided

wall column)• 30 % reduction in capital cost

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A B C

A

B

C

A B

B C

HP LP

Multi-Effect Prefractionator

Forward integrated prefractionator (PF)

Integrated reboiler/condenser

Heat input

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Multi-Effect Prefractionator

Backward integrated prefractionator (PB)

Integrated reboiler/condenser

A B C

A

B

C

A B

B C

HPLP

Heat input

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Energy ConsumptionPercentage Savings of Different Energy Integrated Arrangements

zF Columns = [4 2 1] = [5 4.5 1] = [5 1.5 1] = [2 1.5 1] = [10 5 1]

1/3

1/3

1/3

DS

IS

Petlyuk

DSF/DSB

ISF/ISB

PF/PB

-1.94

0.00

32.80

47.26

32.80

61.73

0.00

-0.51

7.59

7.59

8.21

37.44

-4.98

0.00

12.76

25.56

12.76

47.41

0.00

0.00

39.54

39.54

44.65

59.06

-0.28

0.00

32.71

32.71

34.03

50.05

0.10

0.80

0.10

DS

IS

Petlyuk

DSF/DSB

ISF/ISB

PF/PB

-0.09

0.00

32.99

37.69

32.99

65.55

0.00

-0.03

11.39

11.39

11.63

52.83

-0.23

0.00

12.43

16.20

12.43

54.54

0.00

0.00

47.37

47.34

49.02

71.71

-0.01

0.00

44.23

49.62

44.23

71.80

0.80

0.10

0.10

DS

IS

Petlyuk

DSF/DSB

ISF/ISB

PF/PB

0.00

-10.25

14.96

14.96

15.23

19.92

0.00

-2.14

1.73

1.73

1.77

10.78

0.00

-3.75

19.04

29.55

19.04

32.34

0.00

-17.43

12.45

12.45

12.86

19.68

0.00

-4.07

8.10

8.10

8.18

13.27

The integrated prefractionator arrangement is the best

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Minimum Vapour Flowrate, Vmin

• Vmin as a target - use to compare different designs– Minimum vapour flow at infinite number of stages– Can get within 10 % of Vmin target by using reasonable number of stages– Assumptions: ideal mixtures, constant relative volatility, constant molar

flows, sharp splits

• Can get within 10 % of Vmin-target using reasonable number of stages

E n e rg y

Num

ber o

f sta

ges

V m in

N m in

• Energy (V) vs. number of stages (N)– trade-off between number of stages and

energy– actual V approaches Vmin for N

approximately 2 x Nmin or larger, typically:

2Nmin + 20% Vmin3Nmin + 2 % Vmin4Nmin + 0.2 % Vmin

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Minimum Vapour Flowrate DiagramsA Visual Tool for Process Integration

= DC1/F

VT/F

PA/B

PB/C

PA/C

Vmin(C21)

Vmin(C22)

Vmin (PF/PB)

Vmin(C1)

A B C

A

B

C

A B

B C

C1

C21

C21

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Drawing the Vmin-diagram

Prefractionator column (C1):

Reference: Halvorsen (2003)

= DC1/F

VT/F

PA/B

PB/C

PA/C

zA zA + zB

Ref.: Halvorsen, Skogestad, 20003

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Extending the Vmin-diagram

Upper section main column (C21):

= DC1/F

VT/F

PA/B

PB/C

PA/C

PM3

PM1

PM4

PM2

Lower section main column (C22):

zA zA + zB

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Using the Vmin-diagramVapour Flowrate for Different Distillation Arrangements

• Vmin for different arrangements.

• Visualise how columns are (un)balanced.

• 5 cases identified - different operating options available.

= DC1/F

VT/F

PA/B

PB/C

PA/C

Vmin(C1)

Vmin (DSF/DSB)

Vmin (PF/PB)

Vmin (Petlyuk + ISF/ISB)

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Benefits of the Vmin-diagram

• Easy visualisation of minimum vapour flow.

• Different distillation arrangements are presented in same diagram.

• Tool for further design - balanced/unbalanced columns gives different design options.

• Starting point for further rigorous simulations - Vmin target, optimum recovery = (D/F)

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Control Problems with Heat-Integrated Distillation Columns

• Integrated columns have added complexity. • Integrated columns may be difficult to control as :

– dynamic upsets can propagate back & forth between columns.

– the system is non-linear, multivariable and interacting.

• Energy savings may not be achieved (or may be worse) if the columns are not operated correctly.

• The heat and mass integration of distillation columns causes additional control problems compared to single columns.

It is therefore essential to develop good control systems to ensure satisfactory operation

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Implementing Optimal Operation of Multi-effect Prefractionators

Objective: to implement a simple “optimal” control scheme for integrated distillation systems.

Want to find the controlled variables that will directly ensure optimal economic operation.

“Optimal” - means near-optimal operation. It is economically acceptable to be a certain distance from optimum (but not too far…).

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Objective : Selection of controlled variablesMethod: Self-optimizing control (Skogestad, 2000)

The method of self-optimizing control involves a search for the variables that, when kept constant, indirectly lead to near-optimal operation with acceptable loss.

Loss imposed by keeping constant setpoint for the controlled variable

d* Disturbance d

Cost J

C = constant2,s

C = constant1,s

Re-optimised J (d)opt

Loss

Steady State Optimisation

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The method of self-optimizing control consists of six steps:

1) Finding the DOF for optimisation.

2) Formulation of a of cost function, J, to be maximised for optimal operations &

constraints.

3) Identification of the most important disturbances.

4) Solving the nominal optimisation problem.

5) Identification of candidate controlled variables.

6) Evaluation of loss (at constant setpoints): L = J - Jopt

Ref.: Sigurd Skogestad, "Plantwide control: the search for the self- optimizing control structure”, Journal of Process Control, 10, 2000.

Steady State Optimisation

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DOF analysis for multi-effect columns : DOF = 11 - 4 = 7Objective function:

Operational constraints: – the LP column pressure must be 1 bar– the HP column pressure must be 15 bar– the purity of the products must be 99 mol%– there is a maximum area in the integrated reboiler/condenser– the duty of the HP condenser must equal the duty of the LP reboiler

(equality constraint)– non-negative flows

Process constraints - the mass, energy and component balances

J = pDD + pSS + pBB - pFF - pVV

Steady State Optimisation

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Results from optimisation:• Active constraints:

– Pressure in LP column– Product purity of sidestream– Product purity of bottom stream– Area in integrated exchanger

• Non-active constraints: – pressure in HP column– product purity in distillate

Implement active constraint control + control distillate composition

Steady State Optimisation

DOF Accounts:11 DOF total- 4 active constraints- 4 levels with no steady state effect- 1 fixed feedrate- 1 controlling distillate composition = 1 DOF left for self-optimising control

One DOF left for control - find a self-optimising control variable

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• Calculate loss L = (J - Jopt) for the selected disturbances (zF, F).• Identify the best variable(s) for control, where the loss is small.

Steady State Optimisation

Loss (%)

(feedrate disturbance)

Loss (%)

(composition disturbance)

Controlvariable, c

F + 20 % F - 20% zF,B + 0.1 zF,B - 0.1

PHP 2.50 0.95 21.94 71.70LT,HP/F 0.02 0.01 0.99 InfeasibleDHP/F 0.03 0.02 1.3 1.47xBD,HP 0.02 0.06 26.96 38.71QB,HP Infeasible 24.55 Infeasible 2.44DHP 8.40 19.14 1.33 1.41BHP 20.80 28.11 1.33 1.41QB,HP/F Infeasible Infeasible Infeasible InfeasibleBHP/F 0.03 0.02 1.30 1.47xBB,HP 0.02 0.14 40.92 InfeasibleLT,HP Infeasible 1.99 0.97 InfeasibleT4,HP 3.88 1.09 26.49 InfeasibleXAB,HP Infeasible Infeasible Infeasible Infeasible

Result: Control DHP/F

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Implementing Optimal Operation of Multi-Effect Prefractionators

F

D H PHP LPLC

LC

XC

PC

XCA

XC

LC

X LC

XC

L T,H P

B H PQ B ,H P

X A B ,H P s

(D /F ) s

Q C ,L P

D L P

S L P

B L P

X C

X B

X A

L T,L P

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Dynamic Simulations

0 10 20 30 40 500.98

0.985

0.99

0.995

1Product composition response in LP column

Time (h)

xAxBxC

0 10 20 30 40 500.98

0.985

0.99

0.995

1Product composition response in LP column

Con

cent

ratio

n

Time (h)

xAxBxC

5 % increase in feedrate F

0.5 increase in middle component feed (zF)

• System is controllable.

• System is sensitive to disturbances.

• The control of bottom composition (main column) is poor.

• Use of feed tank to reduce the feed disturbances (zF, F)

• Other control configurations possible.

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An Industrial Separation Example

3 cases for integration:– Column I and II– Column II and III– Column III and IV

Minimum vapour flowrates:– Case 3 has highest savings of

55 %

– PF/PB is the best

– ISF/ISB is 2. best

T = 9 2 C

Ro

E th a n eP ro p a n eB u tan e

E th a n e P ro p a n e

B u ta n e

I

N = 3 2 N = 4 8

I I

T = 2 CCo T = 3 4 CC

o

T = 9 9 C

Ro

P = 2 7 b a r P = 1 3 b a r g a s o l in e

T = 3 7 CCo

P = 4 b a r

N = 4 0

I II

T = 9 4 C

Ro

i- b u ta n e

n -b u ta n e

T = 3 8 CCo

P = 5 .7 b a r

N = 9 2

IV

T = 5 5 C

Ro

H y d ro- ca r b o nf ee d

Case 1 Case 2 Case 3

Vmin/F % Vmin/F % Vmin/F %

DS 4.23 0.0 1.63 0.0 3.38 -0.2

IS 4.33 -2.2 1.69 -3.76 3.38 0.0

DSF/DSB 3.48 17.7 1.17 28.1 2.49 26.4

ISF/ISB 3.43 19.0 1.16 28.5 2.42 28.4

Petlyuk 3.48 17.7 1.17 28.1 2.49 26.4

PF/PB 2.40 43.3 1.02 37.2 1.51 55.3

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Possible Integration for Case III

Indirect Split (IS) PF ISF (existing arrangement)

Energy savings from rigorous simulations:

i-b u ta n en -b u tan eP e n ta n e

P e n ta n e

n -b u ta n e

i-b u ta n e

i-b u ta n en -b u ta n eP e n tan e

i-b u ta n e

n -b u ta n eP e n ta n e

H P L P

T = 3 7 CCo T = 3 8 CC

o

N =4 0 N =9 2

P = 4 b a r

T = 9 4 C

Ro

T = 5 5 C

Ro

I II I IIIVIV

P = 5 .6 b a r

i-b u ta nen-b uta nep e nta n e

i-b uta ne

n-b uta nep e n ta n e

HP LP

ISF PFActual number of stages 42.7 % 28.6 %Infinite number of stages 43.7 % 56.9 %

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Lessons from the Industrial Example

• PF requires more stages to achieve potential energy savings.

• Revamp should therefore be accompanied by an increase in number of stages.

• If sufficient number of stages are allowed the rigorous simulations show that the PF arrangement has high energy savings (57 %).

• The challenge is to implement the arrangement and achieve the savings in practice !

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Main Contributions

• Comparison of multi-effect prefractionator with other multi-effect arrangements and non-integrated arrangements.

• Graphical visualisation of minimum energy for the multi-effect arrangements in a Vmin-diagram.

• Systematic method applied in the selection of controlled variables for the forward integrated prefractionator arrangement. Control variables are identified that will give low energy losses during operation.

• Analysis of the integrated prefractionator arrangement in an industrial setting .

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Concluding Remarks

• Focus of work is on the energy savings of multi-effect systems, especially the integrated prefractionator arrangement.

• Screening of multi-effect arrangements are based on minimum vapour flow at infinite number of stages (PF/PB can achieve up to 70 % savings).

• Minimum vapour flow (Vmin) is a good target, as by adding stages the actual value of vapour flow (V) is usually close to the minimum.

• The energy requirements for multi-effect arrangements are visualised in Vmin-diagrams.

• Selection of controlled variables using the systematic method of self-optimising control.

• Controlling the right variables can give low energy losses during operation.• Industrial case study - high energy savings if sufficient number of stages are

allowed.

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References

Bildea, C.S., Dimian, A.C., 'Interaction between design and control of a heat-integrated distillation system with prefractionator', Tans IChemE, 1999, Vol. 77, Part A, pp. 597-608

Cheng, H. C., Luyben, W., 'Heat-integrated distillation columns for ternary separations', Ind. Eng. Chem. Process Des. Dev., 1985, 24, 707-713

Ding, S.S., Luyben, W., ‘Control of a heat-integrated complex distillation configuration’, Ind. Eng. Chem. Res.¸1990, 29, 1240-1249

Emtir, M., Mizsey, P., Fonyó, Z., ' Economic and controllability investigation and comparison if energy integrated distillation schemes', Chem. Biochem. Eng. Q., 2003, 17(1), 31-42

Halvorsen, I.J, Skogestad, S., ‘Minimum energy consumption in multicomponent distillation. 1. Vmin diagram for a two product column’, Ind. Eng. Chem. Res., 2003, 42, 596-604

Hewitt, G., Quarini, J., Morell, M., ‘More efficient distillation’, The Chemical Engineer, 21 Oct. 1999

Skogestad, S., 2000, Plantwide control: the search for the self-optimizing control structure, J. Proc. Control, Vol.10, 487-507.

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Study Trip….

… sampling at the Glenfiddich Distillery, Scotland and Jameson Distillery, Ireland.

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Practical Considerations for the Multi-Effect Prefractionator

When considering a multi-effect distillation system for a practicalapplication it is important to look at:

• Operating costs (energy)• Capital costs• Total annual costs (operating + capital)• Control• Operability• Flexibility• Integration with overall process

Usually these factors are not independent and a trade-off must be made toachieve an “optimal” design.

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Possible Vmin DiagramsVmin-diagram Limiting

column sectionsPossible use ofexcess vapour

Case 1 (VC1 = VC22 > VC21)

VC22

VC21 Vmin

VC1

C 1

C 21

C 22

PF

a) Intermediate condenserbetween C22 and C21.

b) Overpurify C21 product.

c) Vapour sidestreamproduct.

d) Shorter column sectionC21.

PB

a) Overpurify C21 product.

b) Shorter column sectionC21.

Case 2 (VC1 = VC21 > VC22)

VC21

Vmin

VC22

VC1

C 1

C 21

C 22

PF

a) Overpurify C22 product.

b) Shorter column sectionC22.

PB

a) Intermediate reboilerbetween C22 and C21.

b) Overpurify C22 product.

c) Shorter column sectionC22.

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Case 3 (VC21 = VC22 > VC1)

VC22

VC21

Vmin

VC1

C 2 2

C 1

C 21

PF

Not common, unless αincreases with pressures.

PB

Overpurification in C1 ispossible, but not importantfor final products.

a) Use shorter column C1.

b) Intermediate condenserat top of C21 or C1.

Case 4 (VC21 = VC22 < VC1)

Vmin

VC21 VC22

VC1

C 22

C 1

C 21

PF

a) Intermediate condenserbetween C22 and C21, orbetween C1 and C22.

b) Overpurify productsfrom main column.

c) Vapour sidestreamproduct.

d) Shorter column sectionsC21 and C22.

PB

Not common, unless αincreases with pressures.

Case 5 (VC1 = VC21 = VC22)

VC21

VC22

Vmin

VC1

C 22

C 1

C 21

All column sections arebalanced.

No special measuresneeded.