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Synthesis of Demethanizer

Flowsheets for Low Temperature


Separation Processes

Muneeb Nawaz

Supervisor: Dr Megan Jobson

Centre for Process Integration 2009


L07- 1 PIRC Annual Research Meeting 2009

When a design problem dealing with low temperature separations is approached


in a systematic way, the number of separation alternatives to be studied is
generally very large. The assessment of all possible flowsheets with numerous
options is a time consuming task with a lot of simulations required to select the
economically best option. Therefore, a systematic approach for synthesis is
required to generate effective and economic design of such processes like
demethanizer system with minimal time and effort. To define an optimal
configuration problem, it is necessary to devise an adequate superstructure of the
integrated process with new demethanization processes that is rich enough to
account for all potential configurations and connectivity.

This aim of this research is to extend an existing platform for the design of heat
integrated separation systems to address the demethanizer subsystem which is
characterized by complex interactions between the distillation column and other
flowsheet components, including turbo expander, flash units, multistream
exchangers and refrigeration cycles. Opportunities for heat-integration within the
subflowsheet and also in the overall flowsheet are identified to improve the
economics of the process. Case study demonstrates the strength of the
methodology developed.
Outline

1. Problem Statement
2. Overview of Previous Research
a. Introduction
b. Limitations
3. System Parameter Identification
4. Column Design Method
a. Need for a new method
b. Boundary Value Design Method
c. Case Study
5. Heat Recovery in Multistream Exchanger
6. Overall Flowsheet Synthesis and Optimization
7. Conclusions & Future Work

Centre for Process Integration 2009


L07- 2 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
1. Problem Statement

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L07- 3 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
A Typical Low Temperature Gas
Separation Process

Feed Products
Cold Box

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L07- 4 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes

Low temperature processes usually consist of three main components; the


process i.e distillation, the heat exchange system (cold box) and the refrigeration
system. It is important to note that compression and refrigeration constitute the
main factors that regulate both capital and operating costs in this type of plant.
The continuous emphasis on increasing plant efficiency, driven by the increased
cost of energy and feedstock, has led designers and owners to drive down the
operating and installation cost.
Demethanizer Subsection
For Example

Ethane recycle
Cold box & Expander
Ethane Drying & Off-gas
chilling sales
Ethylene sales

Ethane Storage
cracking
furnaces
Acethylene
LPG reactions
LPG
E/P splitter
Propylene sales
Propane
Buy Propane
cracking Caustic Wash
furnaces
Sell

Propane

C4+ sales
Propane recycle

Ethane/Propane cracking process diagram for ethylene production *

* The Dow Chemical Company, 2005, 17th Annual Ethylene Producers Conference
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L07- 5 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes

The figure illustrates Dows process for an ethylene plant based on a gas
feedstock (ethane and propane). After cracking the feed in the furnace it is sent to
the demethanizer section where the methane\ethane separation takes place at low
temperatures. The C2 splitter follows the demethanizer. The recovered ethane
and propane from deethanizer are recycled to the cracking furnaces.
ABB Lummus Global Residual Recycle High Ethane
Recovery Process *

* Patel et al., US 7,107,788 (2006)


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L07- 6 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes

The figure illustrates ABB Lummus residual recycle process for high ethane
recovery from the natural gas. The process is flexible to recover ethane or
propane depending upon the market conditions. The process utilizes an additional
reflux steam leaner in ethane and propane compared to the demethanizer
overhead stream. The additional reflux stream is taken as a side stream of the
vapour stream from the cold separator.
Self or External Refrigeration?

How many Feed Streams?


Number of Flash Columns
Multistream Heat Exchangers

There are well-established process packages for


low temperature separation systems ...
But
which choice is the best ?

And
can we produce novel designs?
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L07- 7 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Demethanizer Process Issues

Process Selection Issues

P Complex interactions among different components of flowsheet


P Various options for refrigeration
P Structural and parametric degrees of freedom.

Process Design Issues

P Different designs offered by licensors


P Can licensed flowsheets be further optimized?
P Selection of flowsheet package for specific feed and products
specifications

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L07- 8 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes

The heart of every cold train is the demethanizer system and this is where various
technology licensors have different designs. There are many possible options for
optimizing the design of a single column. Depending on the scenario it may be
beneficial to cool the feed, or to split the feed in multiple separators at different
pressures before entering into the column at different stages. The feed cooling is
usually done by heat exchange with the top product in a multistream exchanger.
Similarly the heat for distillation can be provided by side reboilers taking the
energy from the feed stream. As the separation requires very low temperatures,
so there is a need for refrigeration which can be provided by using turbo-
expander or using external refrigeration cycles.
Objective
At preliminary design stage provide a high
level screening and scoping methodology that
would allow energy-efficient and cost-
effective demethanizer flowsheets to be
generated and evaluated.

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L07- 9 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
2. Overview of Previous Research

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L07- 10 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Previous Research

P Synthesis and optimization of low-temperature gas separation


(Jiona Wang, Robin Smith,2005).
P Operating conditions optimization in natural gas processing
plants (Diaz, Serrani, Be Deistegui, 1995)
P Energy expenditure in the thermal separation of hydrocarbon
mixtures using a sequence of heat-integrated distillation
columns (Markowski, M., Trafczynski,M., 2007)
P Automatic design and debottlenecking of ethane extraction
plants (Diaz, Serrani, Bandoni Brignole, 1997)

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L07- 11 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Limitations of the Previous Work

P Multiple feed columns not modelled


P No model for column with side reboilers
P Heat integration through multistream exchangers not
adressed
P No systematic methodology to screen and optimize such
highly integrated flowsheets

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L07- 12 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
3. System Parameter Identification

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L07- 13 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
COMMERCIAL DESIGNS *

P GSP (Gas Subcooled Process)


P CRR( Cold Residual Reflux Process)
P RSV (Recycle-Split Vapor Process)
P RSVE (Recycle-Split Vapor with Enrichment Process)

* Next Generation Processes for NGL/LPG Recovery by ORTLOFF (77th Annual GPA Conference)
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L07- 14 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
COMMERCIAL DESIGNS *

GSP Process CRR Process

* Next Generation Processes for NGL/LPG Recovery by ORTLOFF (77th Annual GPA Conference)
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L07- 15 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes

For ethane recovery the most widely used process is the gas subcooled process.
In this process a portion of the feed gas is condensed and subcooled, fash down
to the tower operating pressure and supplied as an external reflux stream. The
remainder is also expanded by employing a turboexpander) and fed to the tower
at one or more intermediate feed points.

The Cold Residue Recycle (CRR) process is a modification of the GSP process
to achieve higher ethane recovery levels. The process flow sheet is similar to the
GSP except that a compressor and condenser have been added to the overhead
system to take a portion of the residue gas and provide additional reflux for the
demethanizer. This process is attractive for extremely high ethane recovery.
Recovery levels above 98% are achievable with this process.
COMMERCIAL DESIGNS *

RSV Process RSVE Process

* Next Generation Processes for NGL/LPG Recovery by ORTLOFF (77th Annual GPA Conference)
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L07- 16 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes

The Recycle Split-Vapour (RSV) process uses the split vapour feed to provide
the bulk ethane recovery in the tower. The external reflux stream is produced by
withdrawing a small portion of the residue gas, condensing and subcooling and
flashing it down to the demethanizer pressure. The additional cost of adding a
compressor in the CRR process is avoided as well as the shaft power is reduced.

A slight variation of the RSV process is the recycle split-vapor with enrichment
(RSVE) process in which the reflux stream from the residue gas is mixed with
the split vapour feed before being condensed and subcooled. Since the ethane
content of the reflux stream is richer as compared to the RSV process, but the
lower capital cost and simplicity justify the slight loss of ethane recovery.
Comparison of NGL Recovery Processes

Process Recovery % Main feature Comment

When switching to LPG


Gas Subcooled Process Subcooled feed gas as reflux at
90% recovery, propane recovery
(GSP) demethanizer
decreased

Can be operated for near


Uses GSP advantages, while
97% complete rejection of ethane
Cold Residue Reflux (CRR). creating a reflux stream of nearly
while maintain high propane
pure methane.
recovery.

As CRR uses the split-vapour Requires less capital


feed to provide bulk ethane investment. A separate
Recycle Split-Vapour
recovery, but produced by compressor is not needed
Process (RSV) 97%
withdrawing a small portion of for the recycle stream. Can
the residue gas be operated as GSP.

Variation of RSV. The recycle Do not require a separate


Recycle Split-Vapour with stream is mixed with the split exchanger as RSV. Ethane
Enrichment (RSVE) 94% vapour feed before being recovery limited. Lower
condensed and subcooled. capital cost

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L07- 17 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Base case for Sensitivity Analysis*

Process and Apparatus for Hydrocarbon Separation *

* Ohara et al. U.S 7,357,003 (2008)


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L07- 18 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
HYSYS SIMULATION OF BASE CASE

* Ohara et al. U.S 7,357,003 (2008)


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L07- 19 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Process Data
Process Conditions
Feed Gas Composition Feed Conditions
Com ponent Mole Fraction Parameter Value
CO2 0.010 Temperature (C) 17
N2 0.005 Pressure (bar) 62.4
Methane 0.894 Molar Flow Rate (kmol/h) 13700
Ethane 0.049 Sales Gas Conditions
Propane 0.022 Param eter V alue
i-Butane 0.013 Temperature (C) 35
i-Pentane 0.006 P ressure (bar) 60

Process Specifications
P Minimum
P Maximum methane in the demethanizer bottoms: 1.5% mol.
P Apply 2 freeze point in the coldest area
of the plant.
P 75% compressor efficiency and expander efficiency
* Ohara et al. U.S 7,357,003 (2008) Centre
L07- 20 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Sensitivity Analysis

Sensitivity analysis is being performed to identify the key


parameters which affect the flowsheet performance. These
parameters are then examined in order to find the optimal range
of operation conditions.

P Pressure of column
P Feed stage location
P Side reboiler location
P Temperature of high pressure separator
P Vapour split ratio

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L07- 21 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Column Operating Pressure
Effect of Pressure on Compression Power

P High operating pressure is required in 16,000

14,000

order to decrease the compression 12,000


10,000
power but this in turn affects the volatility 8,000

of the key components and therefore the 6,000

4,000

recovery 2,000

-
2,000 2,500 3,000 3,500 4,000 4,500

P The column pressure is varied from Pressure (kPa)

2000 kPa to 4000 kPa keeping a Effect of Pressure on Reboiler Duty

constant pressure drop of 50 kPa across


16,000.0

15,000.0

the column 14,000.0

13,000.0

With the increase in pressure 12,000.0

11,000.0

10,000.0
2,000 2,500 3,000 3,500 4,000 4,500
Pressure (kPa)

P The total power consumption decreased Effect of Pressure on Ethane recovery


by 58% 98.00
97.00

P Ethane recovery also decreased by 8.8% 96.00


95.00
94.00

P Reboiler duty increased by 20% 93.00


92.00
91.00
90.00
89.00
88.00
2,000 2,500 3,000 3,500 4,000 4,500
Pressure (kPa)

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L07- 22 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Side Reboiler Location

Side reboilers in low-temperature distillation columns are particularly


important because they enable:

P Recovery of refrigeration at temperatures lower than the temperature of


the column reboiler
P The cost of generating refrigeration is lowered as the temperature
decreases.
P For example, the generation of a BTU of refrigeration at -35 F requires
roughly twice as much compression horsepower as a BTU of refrigeration
at
P The side reboiler is studied for a fixed temperature difference between
the outlet and inlet stream

* Elliot,D.G., Chen, J.J., and Brown, T.S.,(1996), Fluid Phase Equilibria 116, 27-38
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L07- 23 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Vapour Split Ratio

The split ratio from the low pressure separator is an important factor as
it directly affects the amount of external reflux entering the column.
The split ratio between the column upper feed and the external reflux
stream has been varied from 0.3 to 0.7 to yield the following results

Effect of Vapor Split on Reb duty Effect of Vapor Split ratio on Refrigerant Power

6000
18000

16000 5000
14000
4000
12000

10000 3000
8000
2000
6000

4000 1000

2000
0 0
0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.2 0.3 0.4 0.5 0.6 0.7 0.8
Split Ratio Split Ratio

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L07- 24 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
30
Demethanizer Feed Stage
Effect of Feed stage on Total Compression Power

The top feed point is moved from Stage 2 to 8125

8120

Stage 14. This range of feed points is studied 8115

8110

as the column simulation converges for the 8105

8100

given specifications. As the feed stage 8095

8090

moves down the column the results observed 0 2 4 6


Feed Stage Location
8 10 12 14 16

are listed below:


Effect of feed Stage on Reboiler Duty
14200

14100

P Ethane recovery increases. Larger 14000

13900

changes are seen in the first stages of the 13800

13700

column, and then the changes are very 13600

13500
0 2 4 6 8 10 12 14 16

small after the middle of the column. Feed Stage Location

P There is very slight decrease (0.4%) on Effect of Feed Stage on Ethane Recovery
95.0

the total power consumption 94.5

94.0

P The reboiler duty decreases by 4.3% 93.5

93.0

92.5
92.0

91.5
91.0

90.5
0 2 4 6 8 10 12 14 16

Feed Stage Location

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L07- 25 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Temperature of High Pressure Separator
Effect of Separator Temperature on Compression Power
The temperature has a significant effect as it
9000

affects the ratio of vapor to liquid leaving the 8800

8600
separator, which in turn affects the 8400

performance of the column and the rest of 8200

8000

the 7800

60 The
C.feasible operation range is 7600

7400

above -65 -60 -55 -50 -45

LTS Temperature (C)


-40 -35 -30

minimum approach temperature criterion of


Effect of Separator Temperature on Ethane Recovery

2 C 97.0
96.5
96.0
The results are: 95.5
95.0
94.5
94.0
93.5
P Ethane recovery diminishes from 95 % to 93.0
92.5

91.5 %. 92.0
91.5
-65 -60 -55 -50 -45 -40 -35 -30
P Compression power decreases by 14% Temperature (C)

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L07- 26 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Conclusion of Sensitivity Analysis

At this stage of the process analysis we can conclude that in general


the key parameters that have the most impact on the demethanizer
process performance are:

P The column operating pressure


P The upper feed location in the column
P The location of side reboiler
P Temperature of the high pressure separator, and
P The split ratio between the upper feed and the external reflux stream

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L07- 27 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
4. Column Design Method

a. Need for the new method

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L07- 28 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Design Challenges

P Multiple feed points


P Side reboilers
P External reflux stream
P Large change in relative
volatility over the column

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L07- 29 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Modelling Challenges

Shortcut Models Rigorous Models

P Constant molar overflow and P Solve MESH equations on each


stage
constant relative volatility
assumptions P Requires complex iterative
methods to solve
P Unable to address complex
column configurations P Requires good initial guess
P Give inaccurate design of P Difficult to employ in optimization
demethanizer framework

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L07- 30 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes

At present, there is no shortcut method for determining the minimum ratio for a
complex column like demethanizer. The major characteristics of this column are
the multiple feed, side reboilers and reflux from an external source. The rigorous
methods can be applied to solve the column but the computational time to solve
the model will be increased and that will further increase when this model will be
employed in a flowsheet superstructure and optimized.
Simulation Models of Separation
Options - Shortcut vs Rigorous

Input Output Feature


P Product profile P Simple
Shortcut P Overall heating/cooling P Acceptable accuracy
model P Feed information requirement
P Fast
P Recovery P Approxiamte sizing of
specification device P Suited to preliminary
design
P Constraints P Cost estimation
Rigorous P Complicated
P Product profile P Sensitive to process
model P Local heating/cooling specifications
requirement P Slow and unavoidable
P Final design of device iteration
P Rigorous cost estimation P Suited to device
optimization

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L07- 31 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
4. Column Design Method
b. Boundary Value Design
Method

i) Introduction

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L07- 32 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Introduction
P Analogous to McCabe-Thiele method for column design
P Composition profiles starting from distillate and bottom product
compositions
P Gives column design details e.g. number of stages, heat duty of
condenser and reboiler, minimun reflux etc.

McCabe- Thiele Method Boundary Value Method

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L07- 33 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes

The boundary value method or BVM is first developed for simple column. It
requires the calculation of liquid composition profiles at a given reflux ratio.
Composition profiles of a column show liquid phase compositions on each tray,
which vary from stage to stage because of material and energy balances between
trays and phase equilibrium of the mixture. At a given reflux ratio, the
composition profile of the rectifying section of the column starts from a specified
distillate composition. For the stripping section of the column, the composition
profile starts from a specified bottom composition.
Modeling Column Profile
Continuous Differential Equation

P Develop continuous differential equation for evolution of column profile


(Doherty, 1985)
P Taylor expansion truncated after first term
2
dxi
xi, n+1 = xi,n + h=n (h) + 1 d x2i h=n (h)2 + .....
dh 2 dh

s 1
x i, n + 1 = y i, n + x i, B
s + 1 s + 1

Continuous column profile with independent variable h


Rectifying Section
dx i r 1
= x i y i + x i, D
dh r + 1 r

Stripping Section

dx i s 1
= yi xi + x i, B
dh s +1 s +1

* Levy, S.G., Van Dongen, D.B., and Doherty, M.F., (1985), Ind. Eng. Chem. Fundam. 24, 1463.
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L07- 34 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes

The method is based on finite difference approximations of column profiles in


ordinary differential equation form under the assumption of constant molar
overflow (CMO). Conditions such as minimum reflux are determined using a
boundary value method, in which the rectifying profile for the liquid
compositions is integrated from top to the feed stage while the stripping profile is
integrated from bottom to the feed stage. Thus a feasible column configuration is
one in which the rectifying and stripping profiles intersect and the reflux ratio for
which these profiles just touch each other corresponds to minimum reflux.
Original Boundary Value Design Method
(BVM)
V2, y2

P For ternary mixtures


P First developed for homogeneous 2
L1, x1
azeotropic distillation* D, xD, hD
P Calculation of composition profiles P Composition profiles at a
n
Vn+1 Ln given reflux ratio starting
Hexane yn+1
V
xn from
hn+1
1
Stripping hnL < distillate composition (xD)
profile < bottoms composition (xB)
0.8 Vm Lm+1
ym xm+1
V L
0.6 Rectifying hm hm+1
P Calculate column profiles
profile m
from
B
0.4
< material and energy
F 2 V1, y1, hV balances
1
< Vapour Liquid equilibrium
0.2

0
0 0.2 0.4 0.6 0.8 1 D L2, x2, h2L B, xB, hB
Nonane Pentane

* Levy, S.G., Van Dongen, D.B., and Doherty, M.F., (1985), Ind. Eng. Chem. Fundam. 24, 1463.
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L07- 35 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes

The BVM requires the specification of the product and feed compositions, reflux
ratio and either feed condition or reboil ratio. The next step is to calculate
composition profiles of each column section from material and energy balances
together with vapour liquid. The feasible design is identified from the
intersection between the striping profile and the rectifying profile. Then, we get
column design information such as the number of stages, feed location,
condenser and reboiler duty. Finally, the column designs can be used to evaluate
their capital and operating costs.
4. Column Design Method
b. Boundary Value Design
Method
ii) New Boundary
Value Design Method

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L07- 36 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
New Boundary Value Design Method

Boundary value method has been extended to


# Multicomponent feed mixtures

# Double-feed columns

# Column with side reboilers

# Reboiled absorber column with an


external reflux stream

Software: " Matlab

" HYSYS
< Physical properties

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L07- 37 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes

The major problem with the original BVM method proposed by Doherty et al. is
the visualization of mixtures of more than four components. For this purpose the
concept of minimum distance between a pair of is employed instead of the
strict criterion of the intersection of the composition profiles. The intersection of
the profiles is assessed by calculating the shortest distance in composition space
between the two profiles. If this distance is the same or smaller than the
minimum distance the lines are considered to intersect.
Model Formulation & Implementation

P Model developed in MATLAB involving mass and energy balance

P Stage by stage VLE calculations to avoid constant relative


volatility assumption
P Complex column configuration addressed in the model
P Physical and thermodynamic properties retrieved automatically
from HYSYS

VLE and Enthalpy

MATLAB HYSYS
Mass and Energy
Balance

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L07- 38 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes

The model is originally formulated in MATLAB with the mass and energy
balance original equations. For the calculations of physical properties and vapour
liquid equilibrium, the extensive physical property packages available in ASPEN
HYSYS are used. This is done by developing a link between HYSYS and
MATLAB where HYSYS gives respective equilibrium and enthalpy data for
respective composition from MATLAB
Double-feed Columns

V, y2

I
Upper Feed II
x FU D, xD
L, xR

Lower Feed
xFL

B, xB

P Double-feed column may be more P BVM has been developed for


economic than a single-feed column double-feed columns separating
< Require fewer stages homogeneous mixtures*

* Levy, S.G., Van Dongen, D.B., and Doherty, M.F., (1985), Ind. Eng. Chem. Fundam. 24, 1463.
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L07- 39 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
New boundary value method
Double-feed column

Initialisation steps
Specifications - compositions of upper and lower feeds Identify feasible designs from
- compositions of products the intersection of rectifying
Specify - reflux ratio and reboil ratio or feed quality and middle profiles
The location of lower feed is chosen
such that the smallest number of
stages is required
The intersection point is the upper
Composition profile calculation of stripping, feed location
rectifying and middle sections from Design parameters are obtained
< Material and energy balances < Number of stages in each section
< Upper feed location
< Phase equilibrium
< Feed condition or reboil ratio
Calculate middle profiles starting from various stages < Condenser and reboiler duty
of stripping section

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L07- 40 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes

To get the number of stages and location of both feeds in the column, all
products and feeds are first specified. At a given reflux ratio the stripping and
rectifying profiles are calculated. The middle profile can be generated starting
from a stage either in the stripping section or the rectifying section. The middle
profile calculation from a stage on the stripping section is easier. The lower feed
location becomes a degree of freedom. To choose the lower feed location, middle
profiles are generated starting from different stages in the stripping profiles. The
feasible designs are identified from the intersection between the middle profiles
and the rectifying profiles. Then, the most attractive designs can be chosen.
Double-feed column design by BVM
BVM
FU FL D B
Composition :
Methane 0.8 0.64 0.997 0.98
10 Ethane 0.15 0.26 0.0028 0.012
FU
Propane 0.05 0.9 0 0
D
FL 22 Flow rate (kmol/h) 100 100 145.5 54.5
30 Condenser duty (MJ/h) 202.8
Reboiler duty (MJ/h) 1368
B
HYSYS
Reflux ratio = 0.22 FU FL D B
Composition :
Methane 0.8 0.64 0.997 0.98
Ethane 0.15 0.26 0.0028 0.012
Propane 0.05 0.9 0 0
Flow rate (kmol/h) 100 100 145.5 54.5
Condenser duty (MJ/h) 205.3
Reboiler duty (MJ/h) 1372

P Results from HYSYS are in good agreement with the specified


compositions for the design method

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L07- 41 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
4. Column Design Method
C. Case Study

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L07- 42 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Pressure : 30 bar, Reflux ratio =0.2516,
Column Specificaion : 94.5% Recovery of Ethane
in Bottom product Top Product

Feed Data
Upper Feed Flowrate, FU = 1000kmol/hr
Upper Feed Composition (Mole Fraction) FU
Methane: 0.8595, Ethane: 0.102,
Propane : 0.023, i-Butane: 0.0155 FL

Lower Feed Flowrate, FL = 1000kmol/hr


Lower Feed Composition (Mole Fraction) Q1
Methane: 0.62, Ethane: 0.21,Propane : 0.10, Q2
i-Butane: 0.07
Bottom
Side Heaters Product
Q1at 11th stage = 1200 MJ/hr
Q2 at 16th stage = 1000 MJ/hr

Ref: Foglietta et al. US 7,159,417 (2004)

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L07- 43 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Validation of Model

BVM Resu lts HYSYS Results % Difference

Num ber of Stages 23 23 -


Upper Fee d Stage Location 6 6 -

Lower Fee d Stage Location 12 12 -

Condenser Duty (MJ /hr) 2075 2087 0.6


Reboile r Duty (M J/hr) 11 079 11 083 0.035

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L07- 44 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Comparison of Models

Column Composition Profiles


1.0
0.9 Methane(HYSYS)
0.8 Ethane(HYSYS)
0.7 Propane(HYSYS)
0.6 i-Butane (HYSYS)
0.5 Methane (BVM)
0.4 Ethane (BVM)
Propane (BVM)
0.3
i-Butane (BVM)
0.2
0.1
0.0
Top 1 3 5 7 9 11 13 15 17 19 21 Bottom

Stages

Comparison of composition profiles obtained from


BVM with HYSYS
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L07- 45 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Summary

P Simplified model for demethanizer has been developed.


Model is suitable for multicomponent systems
P Model represents process behaviour satisfactorily
P Model accommodates complex column features such as
multiple feed, intermediate heating and external reflux
stream
P Complex column simulation has been tested against
HYSYS simulation. Model represents column behaviour
well
P New BVM can be used for assessing the feasibility of a
proposed specification and setting up designs
< Number of stages
< Feed locations
< Reboiler/condenser duties

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L07- 46 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
5. Heat Recovery in Multistream
Exchangers

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L07- 47 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Heat Recovery in Multistream Exchanger

P Obtain Process Heat and Material Balances

< Analysis of the entire process to obtain a heat and material


balance for each operation. The heat and material balances
should be performed as if all of the exchanger duties were
independent. For this step, refrigeration and external loads are
supplied independent of the process and should be ignored.

P Tabulate Duties
< The second step is to list the inlet and outlet temperatures and
duties for all units involving heat exchange.

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L07- 48 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Heat Recovery in Multistream Exchanger

P Match Duties and Temperatures


< Matching the duties by starting with the largest cooling loads.
< If heating loads with temperatures lower than the exit temperature
of the cooling load are available, these should be accumulated until
the duty approximately matches the cooling load. Any excess
cooling load will have to be handled by refrigeration.

P Balance Loads
< Heating and cooling loads balanced by separately summing the
duties on each side of the exchanger
< Residual duty must be reduced to zero by refrigeration or a heat
source

P Temperature cross within the exchanger


< Phase change or large flow rates across a narrow temperature
range results in the cumulative cooling load temperature drops
below the cumulative heating load temperature

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L07- 49 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Multi-steam exchanger design according to
the balanced composite curves

H1
H2 H
H3
C1
C2
H3 H3 H2 H1 H3 H1
H2
Cold Utility
Hot Utility
C1 C2
C1 C2
C2

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L07- 50 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
6. Overall Flowsheet Synthesis and
Optimization

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L07- 51 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Synthesis Methodology

Develop simplified model for demethanizer


< New model compares well with rigorous simulation results for simple
columns
Optimise column design parameters with simplified model
Develop systematic approach for generation and evaluation
of flowsheets
Develop optimisation framework for overall flowsheet
synthesis and optimization

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L07- 52 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Base Case Simulation

Process Conditions
Feed Gas Composition Feed Gas Conditions
Com pone nt M ole Fraction Param e ter Condition
Temperature (C) 25
Methane 0.865
Pressure (bar) 60
Ethane 0.075 Molar Flow Rate (kmol/h) 36000
Propane 0.035
i-Butane 0.015
n-Butane 0.006
i-Pentane 0.004
Demethanizer Conditions
Parameter Condition
Number of trays 25
Operating pressure (kPa) 3000
Pressure drop (kPa) 50

Product Specifications: methane to ethane in bottom =1.5%


Ethane Recovery = 90%
* Campbell et al. US 4,157,904 (1979)
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L07- 53 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes

The feed to the gas subcooled process for ethane recovery based on US patent
4,157,904 is selected as the case study. The objective has set to be minimising
the operating cost of the system which is essentially reducing the compression
power and reboiler duty for the system. Steam and cooling water next to
refrigeration system are provided as utility for the system. Overall ethane
recovery of more than 90% is used as a specification for the process. The process
is selected as it is the most widely employed process for NGL recovery, with all
the necessary flowsheet components present.
Base Case Simulation

Gas subcooled process* is selected as the base case for the study and
simulated with the shortcut models developed in MATLAB

Reflux Exchanger

Sales Gas

Expander
Inlet Gas Flash
Column

Multistream
Exchanger

Bottom Product
* Campbell et al. US 4,157,904 (1979)
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L07- 54 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Comparison of Model with Rigorous
Simulation

Model HYSYS

Methane Recovery in Sales Gas 99.40 99.7


Ethane Recovery in NGL 90.2 90.4
Total Shaft Power 38.12MW 38.4 MW

Reboiler Duty 57420 MJ/hr 58870 MJ/hr


Number of Trays of Demethanizer 25 25

Model shows good agreement with rigorous HYSYS simulation

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L07- 55 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Optimization of the Process

P The total shaft power required for the recompressor and


refrigeration need to be optimized and compared against base
case
P Design variables
< Column operating pressure (10 ~40 bar)
< Flash column temperature (-20 ~ -40 C)
< Side reboiler location ( 5th ~ 20th stage)
< Upper feed to reflux ratio (0.2 ~ 0.8)

P Objective function: Minimize total shaft power


P Constraint: Ethane recocery in NGL > 90%

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Optimization Approach
Base Case
Initial conditions
and structure

Objective Function

Minimize total Optimization Variables


shaft power Algorithm
(SQP) Constraints

Optimum
demethanizer
flowsheet

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Optimization Results

Condition Power (MW)

Base case without optimization 38.12

Base case with optimization 33.6

Optimized Variables
P Column pressure = 25 bar
P Side reboiler location = 8th stage
P Flash column temperature = -30 C
P Upper feed to reflux ratio = 0.6
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L07- 58 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Now
Lets try a different configuration to
increase the ethane recovery

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L07- 59 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
RSVE Process Optimization

* Campbell et al. US 4,854,955 (1989)


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L07- 60 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Comparison of Results with Rigorous
Simulation

Model HYSYS
Methane Recovery in Sales Gas 99.8 99.8
Ethane Recovery in NGL 94.3 94.2
Total Shaft Power 42.8 MW 42.4 MW

Reboiler Duty 70280 MJ/hr 69820 MJ/hr


Number of Trays of Demethanizer 30 30

P Increase of ethane recovery compared to GSP at the expense of


increased shaft power and reboiler duty
P The model shows good agreement with rigorous HYSYS simulation

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L07- 61 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Optimization Results
Optimization condition Power (MW)

Total shaft power without optimization 42.8

Total shaft power with optimization 36.6

Optimum values of variables


P Column pressure = 30 bar
P 1st side reboiler location = 12th stage
P 2nd side reboiler location = 20th stage
P Flash column temperature = -42 C
P Upper feed to reflux ratio = 0.75
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L07- 62 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Summary
Without
GSP Optimization 38.2
(90.2% Ethane
Recovery ) With
Optimization 33.6
Total Power
Requirement Without
(MW) Optimization 42.8
RSVE
(94.3% Ethane
Recovery ) With
Optimization 36.7

P Optimization brings significant benefits


P Trade-off between power input and ethane recovery
P Need to optimize total cost
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L07- 63 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
7. Conclusions and Future work

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L07- 64 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Conclusions

P Shortcut models developed for demethanizer, flash column,


turbo-expander and compressor
P Heat recovery issues with multistream exchangers addressed
P Different flowsheet configurations are modelled and validated
against rigorous simulation
P Important variables affecting the overall process are identified
P Different flowsheet configurations are optimized to decrease the
total power requirement

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L07- 65 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Future Work

P Development of superstructure to accommodate all important


features for synthesis and optimization of flowsheet
P Development of systematic methodology to create heat
integration opportunities
P Application of stochastic optimization methods for structural and
parametric optimization
P Application of developed methodology to industrial case studies

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L07- 66 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
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L07- 67 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes

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