ENERGY SAVINGS IN

MISCELLA DISTILLATION

MISCELLA DISTILLATION
UNIT PROCESSES

Oil Dryer

Oil Stripper

2nd Stage Evaporator

Flash Pre-evaporator

Miscella/Oil HX

1st Stage Evaporator

Miscella Tank

MISCELLA DISTILLATION
OIL CONCENTRATIONS
Miscella Concentration Profile

95
90

90

to miscella/oil HX

to flash preevaporator

98

99.7

99.93

99.93

to oil stripper

to oil dryer

to miscella/oil HX

to refinery

25

to 1st stage
evaporator

to 2nd stage
evaporator

MISCELLA DISTILLATION
TEMPERATURES
Miscella Temperature Profile
220

220
210

165

170
160

135
120

to 1st stage
evaporator

to miscella/oil HX

to flash preevaporator

to 2nd stage
evaporator

to oil stripper

to oil dryer

to miscella/oil HX

to refinery

MISCELLA DISTILLATION
ENERGY INPUT
Miscella Distillation Energy Input
mm BTU / hr (100,000 bpd soy plant)

11.65

recovered heat sources

fresh steam
2.58
1.26

1.13
0.32
1ST STAGE EVAPORATOR

MISCELLA/OIL HX

FLASH PRE-EVAPORATOR

2ND STAGE EVAPORATOR

OIL STRIPPER

MISCELLA DISTILLATION
ENERGY INPUT
Miscella Distillation Energy Input
15%

7%

1ST STAGE EVAPORATOR

MISCELLA/OIL HX

2%

FLASH PRE-EVAPORATOR
2ND STAGE EVAPORATOR
7%

OIL STRIPPER

69%

1st Stage Evaporator is Key!

6

OPTIMIZING THE
1ST STAGE EVAPORATOR
Optimizing 1st Stage Evaporator heat transfer is key to
minimizing distillation energy consumption
Heat transfer = Q = U x A x T
1. Optimize U by keeping the tubes clean
- minimize tube fouling with a good DT vapor scrubber
2. Optimize A by installing a large tube surface area
3. Optimize T by maximizing the vacuum
- send coolest cooling water to the vacuum condenser
- minimize vacuum condenser pressure drop
- only condense hexane vapor in the vacuum condenser
7

OPTIMIZING THE
1ST STAGE EVAPORATOR
1. Optimize U by keeping the tubes clean

Water-spray type
Vapor Scrubber
to remove meal
fines in DT vapors
to 1st Stage
Evaporator

OPTIMIZING THE
1ST STAGE EVAPORATOR
2. Optimize A by installing a large tube surface area

OPTIMIZING THE
1ST STAGE EVAPORATOR
3. Optimize T by maximizing the vacuum
Impact of Vacuum on 1st Stage Evaporator

If vacuum is 15 Hg on 1st Stage Evaporator, then boiling

point of hexane in tubes is 118 F and DT vapors on shell
are 143 F, so T = 25 F in evaporator.
If vacuum is 18 Hg on 1st Stage Evaporator, then boiling
point of hexane in tubes is 106 F and DT vapors on shell
are 143 F, so T = 37 F in evaporator.
This 3 Hg increase in vacuum increases the heat
transfer capability by 37/25 = 1.48 = 48%!

OPTIMIZING THE
1ST STAGE EVAPORATOR
3. Optimize T by maximizing the vacuum
- send coolest cooling water to the vacuum condenser

Coolest water near vapor exit

11

OPTIMIZING THE
1ST STAGE EVAPORATOR
3. Optimize T by maximizing the vacuum
- minimize vacuum condenser pressure drop

A split flow vacuum vapor

condenser reduces pressure
drop through the condenser
by a factor of 4!

12

OPTIMIZING THE
1ST STAGE EVAPORATOR
3. Optimize T by maximizing the vacuum
- only condense hexane vapor in the vacuum condenser
Impact of water in vapors to Vacuum Condenser

To achieve 18 Hg vacuum in the 1st Stage Evaporator if

there is an azeotropic hexane/water vapor going to the
vacuum condenser, 72 F cooling water is required
To achieve 18 Hg vacuum in the 1st Stage Evaporator if
there is pure hexane vapor going to the vacuum
condenser, only 86 F cooling water is required

OPTIMIZING THE
1ST STAGE EVAPORATOR
3. Optimize T by maximizing the vacuum
- only condense hexane vapor in the vacuum condenser
Impact of Cooling Water Temperature on
Vacuum
140
130

degrees F

120

Condenser
T = 20 F

110
100
90
80
70

21
Hg

18
Hg

60
50
0

Hexane Boiling Point

10

12
14
16
18
inches Hg Vacuum

72 F cooling water

20

22

24

26

28

30

Hexane/Water Azeotrope Boiling Point

Cooling Water Temperature

14

OPTIMIZING THE
1ST STAGE EVAPORATOR
3. Optimize T by maximizing the vacuum
- only condense hexane vapor in the vacuum condenser
Impact of Cooling Water Temperature on
Vacuum
140
130

Condenser
T = 20 F

degrees F

120
110
100
90

86 F cooling water

80
70

15
Hg

60
50
0

Hexane Boiling Point

10

18
Hg

12
14
16
18
inches Hg Vacuum

20

22

24

26

28

30

Hexane/Water Azeotrope Boiling Point

Cooling Water Temperature

15

OPTIMIZING THE
1ST STAGE EVAPORATOR
100% hexane vapor

70% water vapor

30% hexane vapor

How to only condense

hexane vapor in the
vacuum condenser?

Oil Dryer

Oil Stripper

2nd Stage Evaporator

1st Stage Evaporator

Vacuum Condenser

DT
16

OPTIMIZING THE
1ST STAGE EVAPORATOR
100% hexane vapor

70% water vapor

30% hexane vapor

Vacuum Condenser
Install a
Stripper Condenser !

Oil Dryer

Oil Stripper

2nd Stage Evaporator

1st Stage Evaporator

Stripper Condenser

DT
17

OPTIMIZING THE
1ST STAGE EVAPORATOR
1. Optimize U by keeping the tubes clean
- minimize tube fouling with a good DT vapor scrubber
2. Optimize A by installing a large tube surface area

3. Optimize T by maximizing the vacuum

- send coolest cooling water to the vacuum condenser
- minimize vacuum condenser pressure drop
- only condense hexane vapor in the vacuum condenser

18

OPTIMIZING DOWNSTREAM
MISCELLA DISTILLATION
Miscella Distillation
Energy Input
Miscella/Oil
Interchanger
mm BTU / hr (100,000 bpd soy plant)

11.65

2.58
1.26

1.13
0.32
1ST STAGE EVAPORATOR

MISCELLA/OIL HX

FLASH PRE-EVAPORATOR

2ND STAGE EVAPORATOR

OIL STRIPPER

19

OPTIMIZING DOWNSTREAM
MISCELLA DISTILLATION

Miscella/Oil Interchanger
210 F

oil

Miscella Distillation Energy

Input

165 F

15%

Miscella/Oil HX

7%
2%
7%

69%

miscella

120 F

160 F
20

OPTIMIZING DOWNSTREAM
MISCELLA DISTILLATION
Miscella Distillation
Energy Input
Flash Steam
Pre-Evaporator
mm BTU / hr (100,000 bpd soy plant)

11.65

1.13

2.58
1.26

0.32
1ST STAGE EVAPORATOR

MISCELLA/OIL HX

FLASH PRE-EVAPORATOR

2ND STAGE EVAPORATOR

OIL STRIPPER

21

OPTIMIZING DOWNSTREAM
MISCELLA DISTILLATION

Flash Steam Pre-Evaporator

95% oil / 170 F

condensate
tank flash
miscella

Flash Pre-evaporator

212 F

Miscella Distillation Energy

Input
15%

7%
2%
7%

69%

90% oil / 165 F

22

OPTIMIZING DOWNSTREAM
MISCELLA DISTILLATION
Distillation
Energy Input
2ndMiscella
Stage
Evaporator
mm BTU / hr (100,000 bpd soy plant)

11.65

2.58

1.26

1.13
0.32
1ST STAGE EVAPORATOR

MISCELLA/OIL HX

FLASH PRE-EVAPORATOR

2ND STAGE EVAPORATOR

OIL STRIPPER

23

OPTIMIZING DOWNSTREAM
MISCELLA DISTILLATION

2nd Stage Evaporator

98% oil / 220 F

miscella

2nd Stage Evaporator

fresh
steam

Miscella Distillation Energy

Input
15%

7%
2%
7%

69%

95% oil / 170 F

24

OPTIMIZING DOWNSTREAM
MISCELLA DISTILLATION

Oil Stripper

Miscella Distillation Energy Input

mm BTU / hr (100,000 bpd soy plant)

11.65

2.58
1.26

1.13
0.32
1ST STAGE EVAPORATOR

MISCELLA/OIL HX

FLASH PRE-EVAPORATOR

2ND STAGE EVAPORATOR

OIL STRIPPER

25

OPTIMIZING DOWNSTREAM
MISCELLA DISTILLATION
oil

Oil Stripper

220 F

steam

Miscella Distillation Energy

Input

Oil Dryer

Oil Stripper

15%

7%
2%
7%

69%

220 F

oil
26

OPTIMIZING DOWNSTREAM
MISCELLA DISTILLATION

Sieve Tray Oil Stripper

27

OPTIMIZING DOWNSTREAM
MISCELLA DISTILLATION

Stripper Condenser Heat Recovery

70% water vapor
30% hexane vapor

hexane vapor

Stripper Condenser
Oil Stripper

condensed
water

ejector
motive
steam

28

OPTIMIZING DOWNSTREAM
MISCELLA DISTILLATION

Stripper Condenser Heat Recovery

90 F cool water

Stripper Condenser

120 F warm
water

Tank

1st DC Heater Coil

70 F air

SOYBEAN PLANT
OPTION
29

OPTIMIZING DOWNSTREAM
MISCELLA DISTILLATION

Stripper Condenser Heat Recovery

90 F solvent

120 F solvent

Stripper Condenser

Solvent Heater

Work Tank

Extractor
CANOLA PLANT
OPTION
30

ENERGY SAVINGS IN
MISCELLA DISTILLATION

31