Академический Документы
Профессиональный Документы
Культура Документы
Muneeb Nawaz
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
Feed Products
Cold Box
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
* The Dow Chemical Company, 2005, 17th Annual Ethylene Producers Conference
Centre
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 *
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?
And
can we produce novel designs?
Centre
L07- 7 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Demethanizer Process Issues
Centre
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.
Centre
L07- 9 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
2. Overview of Previous Research
Centre
L07- 10 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Previous Research
Centre
L07- 11 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Limitations of the Previous Work
Centre
L07- 12 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
3. System Parameter Identification
Centre
L07- 13 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
COMMERCIAL DESIGNS *
* Next Generation Processes for NGL/LPG Recovery by ORTLOFF (77th Annual GPA Conference)
Centre
L07- 14 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
COMMERCIAL DESIGNS *
* Next Generation Processes for NGL/LPG Recovery by ORTLOFF (77th Annual GPA Conference)
Centre
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 *
* Next Generation Processes for NGL/LPG Recovery by ORTLOFF (77th Annual GPA Conference)
Centre
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
Centre
L07- 17 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Base case for Sensitivity Analysis*
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
P Pressure of column
P Feed stage location
P Side reboiler location
P Temperature of high pressure separator
P Vapour split ratio
Centre
L07- 21 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Column Operating Pressure
Effect of Pressure on Compression Power
14,000
4,000
recovery 2,000
-
2,000 2,500 3,000 3,500 4,000 4,500
15,000.0
13,000.0
11,000.0
10,000.0
2,000 2,500 3,000 3,500 4,000 4,500
Pressure (kPa)
Centre
L07- 22 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Side Reboiler Location
* Elliot,D.G., Chen, J.J., and Brown, T.S.,(1996), Fluid Phase Equilibria 116, 27-38
Centre
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
Centre
L07- 24 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
30
Demethanizer Feed Stage
Effect of Feed stage on Total Compression Power
8120
8110
8100
8090
14100
13900
13700
13500
0 2 4 6 8 10 12 14 16
P There is very slight decrease (0.4%) on Effect of Feed Stage on Ethane Recovery
95.0
94.0
93.0
92.5
92.0
91.5
91.0
90.5
0 2 4 6 8 10 12 14 16
Centre
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
8600
separator, which in turn affects the 8400
8000
the 7800
60 The
C.feasible operation range is 7600
7400
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)
Centre
L07- 26 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Conclusion of Sensitivity Analysis
Centre
L07- 27 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
4. Column Design Method
Centre
L07- 28 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Design Challenges
Centre
L07- 29 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Modelling Challenges
Centre
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
Centre
L07- 31 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
4. Column Design Method
b. Boundary Value Design
Method
i) Introduction
Centre
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.
Centre
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
s 1
x i, n + 1 = y i, n + x i, B
s + 1 s + 1
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.
Centre
L07- 34 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
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.
Centre
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
Centre
L07- 36 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
New Boundary Value Design Method
# Double-feed columns
" HYSYS
< Physical properties
Centre
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
MATLAB HYSYS
Mass and Energy
Balance
Centre
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
* Levy, S.G., Van Dongen, D.B., and Doherty, M.F., (1985), Ind. Eng. Chem. Fundam. 24, 1463.
Centre
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
Centre
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
Centre
L07- 41 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
4. Column Design Method
C. Case Study
Centre
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
Centre
L07- 43 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Validation of Model
Centre
L07- 44 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Comparison of Models
Stages
Centre
L07- 46 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
5. Heat Recovery in Multistream
Exchangers
Centre
L07- 47 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Heat Recovery in Multistream Exchanger
P Tabulate Duties
< The second step is to list the inlet and outlet temperatures and
duties for all units involving heat exchange.
Centre
L07- 48 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Heat Recovery in Multistream Exchanger
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
Centre
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
Centre
L07- 50 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
6. Overall Flowsheet Synthesis and
Optimization
Centre
L07- 51 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Synthesis Methodology
Centre
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
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)
Centre
L07- 54 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Comparison of Model with Rigorous
Simulation
Model HYSYS
Centre
L07- 55 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Optimization of the Process
Centre
L07- 56 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Optimization Approach
Base Case
Initial conditions
and structure
Objective Function
Optimum
demethanizer
flowsheet
Centre
L07- 57 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Optimization Results
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
Centre
L07- 58 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Now
Lets try a different configuration to
increase the ethane recovery
Centre
L07- 59 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
RSVE Process Optimization
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
Centre
L07- 61 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Optimization Results
Optimization condition Power (MW)
Centre
L07- 64 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Conclusions
Centre
L07- 65 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Future Work
Centre
L07- 66 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes
Centre
L07- 67 Synthesis of Demethanizer Flowsheets for Low Temperature Separation Processes