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Printed in Great Britain. @ 1982 Pergamon Press Ltd.
TRULS GUNDERSEN*
Department of Chemical Engineering, University of Trondheim, Norway
Abstract-It is shown that failures in flash calculations (Ki --, 1.0) when cubic equations of state are
used to estimate equilibrium K-values, result from two main deficiencies. One is the well-known
problem of guessing good starting values of the phase compositions at high pressure. The other is
that regular methods for solving the cubic equation in the compressibility often lead to a wrong
type of root (i.e. vapour or liquid). An algorithm without these deficiencies is presented.
Scope-Cubic equations of state (e.g. Soave-Redlich-Kwong and Peng-Robinson) are the most
popular methods among chemical engineers for estimating K-values of hydrocarbon mixtures at high
pressure. In spite of this, many flash calculation packages and even commercial flowsheet simulators
that have implemented these methods fail to perform properly at pressures exceeding 5040% of the
critical pressure of the mixture. In program manuals this failure is referred to as the problem of all
K-values approaching 1.0. Disappointingly, few seem to have looked behind the curtain to find out
why this is so.
This article discusses why flash calculations fail and how to implement the SRK method for use
at high (near critical) pressure. A system of eight components with 72.8 mole % methane is used to
illustrate the techniques and results, together with a three-component system of ethane, propane and
n-butane. To compare the results, calculations were also carried out with the MINISIM program,
developed at Oklahoma State University.
Conclusions and Significance-There seems to be some kind of confusion in the literature about the
connection between the number of roots arising from the equations of state and the actual number of
phases in the system. This work has shown that the Soave-modified Redlich-Kwong equation of
state becomes monotonic at moderate and high pressure. This may happen for one of the phases or
both and well inside the two-phase region.
In cases where the equation is not monotonic, but still only has one root, failure of the calculation
is avoided by using maximum or minimum points instead of the actual solution if this root is a wrong
type (vapour/liquid) of compressibility.
The proposed algorithm is able to estimate the phase diagram for the two test systems within
from 0.2 to 2.0 atm from the critical point, using a sequential technique with stepwise calculations
from low (1 atm) to high (near critical) pressure. The advantage of this method is the good initial esti-
mate of the phase compositions available from the previous calculation.
245
246 Trms GUN~IER~EN
A5 = -flf (W
or in (2)-(4) iterations by a third order method presented
Numerical aspects of the implementation of cubic equations of state in flash calculation routines 241
derivatives of the function looking for a liquid compressibility with F(Z) of the
shape B, a general routine finds ZLIQ = Z,.
F(Z)=z3-ZZtQ~Z-R (10) An alternative approach is to say the the vapour-like
solution of case A has slipped from the point Z,, and
and in particular the first and second that the liquid-like solution of case B has slipped from
the point Zr. The values of Z, and Z2 are given by Eq.
13. The cases A and B occur only at low and moderate
F(Z)=3.Z*-2.Z+Q (11) pressure levels and result basically from poor starting
F(Z)=6.Z-2 (12) values of the phase compositions. It is found from
experience that choosing Z2rather than Z, (ZVAP) and Z,
will indicate the possibility of one or more roots in the rather than Z, (ZLIQ) has a positive effect on the iteration
procedure. As a matter of fact, the iteration otherwise
range of Z from 0 to 1.0.
At low pressure, Eq. 10 will take a form as given by breaks down with the typical solution ZLIQ = ZVAP and
Fig. l(a), while increasing pressure will make the func- K, --) 1.0(i = 1, NC). Cases A and B can easily be detected
tion monotonically increasing as shown in Fig. l(b). by evaluating the function F(Z) (Eq. 10) at Z, and Z2.
The point of inflection (F(Z) = 0) for the SRK equa- In the general case, the solution is found by a third-
tion is at Z = l/3 for all values of xi, yi, P and T. The order method, (Eq. 2(b)) which is very fast (2-3 itera-
Z-values of the extreme points (F(Z) = 0) are given by: tions) because of the straightforward nature of the first
(Eq. 11) and thesecond (Eq. 12) derivatives and the
linear nature of F(Z) to the left of Z1 and to the right of
Z2. Starting values are Z = 0 for liquid phase and Z = 1
(13) for vapour phase.
Algorithms for the solution of the cubic equations of
state are seldom published, and this is an indication that
Obviously, if Q = l/3 the extreme points and the point of analytical solution techniques are most common. One
inflection coincide at Z = l/3. If Q > l/3 then F(Z) is numerical algorithm is suggested by Buthod et al. [8], but
monotonically increasing (Fig. l(b)) and there is only this is hardly the most time-saving routine. They chose a
one root possible. Coward et al.[3] have found the values method of ten steps of interval halving followed by
of Q and R that give rise to one or three solutions. If application of Newtons method.
Q < l/3 there is still a possibility of finding just one root.
This is illustrated in Fig. 2. When seeking a vapour PRoFWErlALGoRrm.M
compressibility with F(Z) of the shape A, most solution Estimation of compressibility factors should be done
routines select 2, as ZVAP. In the same manner, when by a subroutine whose input data are the parameters Q
Numerical aspects of the implementation of cubic equations of state in flashcalculationroutines 249
A: Vapour phase
Z3: unacceptable root ZZ: chosen value
B: Liquid phase
s1
. chosen value
Z6: unacceptable root z,:
z
I I I I I
kI.0 .2 .4 .6 .8 4.0
and R together with a key (IPH) for actual phase. become zero if the following equation is satisfied:
(IPH = O+ liquid, IPH = 1+ vapour). The algorithm,
which has been tested and found to perform properly, is Z,-Z,tQ.Z2-R..,=O. (1%
presented in Fig. 3. The basic idea has been presented in
the previous section, and only a few details about the We already have:
algorithm is mentioned below:
(i) If Q 2 l/3, then F(1/3) is calculated in order to Z,-Z,2tQ~Z2-R,,,~=F2. (16)
determine whether the (only) solution is to the left or to
the right of the point of inflection. A proper starting This leads to a simple correction scheme:
point, Z,, is found to be:
F3 = F(1/3)
P-
Yes no
F,>O
3. order method z = z, z = 22
CL3 END
Table 2. Compositionof test mixtureI The number of iterations increases as we approach the
critical point:
Component mole 9:
l- 50 atm: 2-4 iterations
Nitrogen 0.54 50-100 atm: 4-8 iterations
Methane 72.80 100-150 atm: 8-12 iterations
150-170 atm: 12-30 iterations,
Ethane 5.46
TEMPERATURE (K)
Fig. 4. Phase diagram for test mixture I (8 components). The curves show vapour fractions of 0,20,40,60,80 and
100mole %.
8
2.
G
r:.
t2
I?.
- i 40 400 i 000
PRESSURE CATM I
Fig. 5. K-v&es for methane(A), n-butane (0) and heptane (t) in the mixtureof 8 componentsat 320K.
acceptable results. Figure 5 shows K-values for At high pressure, the K-values do not behave normally
methane, n-butane and heptane in mixture I at 320K. outside the two-phase region. At pressures exceeding 60
The shapes of the curves agree well with theory, and the per cent of the critical pressure, the iteration outside the
K-values approach 1.0 when the pressure comes close to two-phase region fails. For example, at temperatures
its critical value. above the dew-point, the mole fractions of the liquid
In Fig. 6, compressibility factors of the two phases are phase and the K-values tend to continue changing until
plotted against pressure at 320K. When the pressure all K-values come close to 1.0 and the compositions of
approaches its critical value, the two compressibility the two phases become identical. It was found that the
factors meet at a value of about 0.68. only possible way of reaching the critical region of the
100 150 2
PRESSURE t ATrl I
mixture was to do a sequential calculation, starting at low Numerical investigation of the g-component system
pressure (1 atm) and then increasing the pressure step- showed that F(Z) for the liquid phase became monotonic
wise until the actual pressure was reached. The equili- for pressures above lOatm, while the vapour phase
brium compositions of the previous calculation are used resulted in a monotonic F(Z) for pressures above
as starting values of the new calculation. The tem- 145atm. The number of phases in the system therefore
perature for each calculation is chosen in a way that has nothing to do with the number of roots of the SRK
keeps the mixture at each calculated point in the two- equation of state. This trend should also apply to the PR
phase region. This can be illustrated by the following: A equation of state. Maddox and Erbar[l4] present the
flash calculation at 170atm and 340K was successfully typical behaviour of cubic equations of state as having
carried out after having done two initial calculations three roots in the two-phase region and one root (mono-
(1 atm, 200 K and 140atm, 340 K). tonic function) in the single phase regions, but this is not
The critical region of the ethane (0.4)-propane (0.4)- correct.
n-butane (0.2) mixture investigated by Coward and Results have proved the advantage of using the
Webb[4], was analysed. According to them, the Chao- extreme points Z1 and Z, in Fig. 2 as roots whenever the
Seader correlation using the Redlich-Kwong equation of correct root gives physically unacceptable values of
state gave disturbing and physically unacceptable results the compressibility factors. This is what Coward et al. [3]
for pressures exceeding 40atm. Using the Orye[9] vari- characterize as embarrassing without telling the reader
ant of the Benedict-Webb-Rubin equation, Coward and what actions to take. Boston and Mathias[13] have
Webb estimated the critical pressure and temperature to reported a similar technique when roots are lost, and
be 50.5 atm and 365.4 K. in their work with the ASPEN program, they have
With the proposed algorithm, high-pressure flash cal- experienced the same advantage as in the work with the
culations were performed and the results are given in proposed algorithm. They do not mention that this
Fig. 7. The SRK method estimated the critical tem- mathematical manipulation in some cases can lead to
perature to be in the region 366.8-367.1 K and the critical negative arguments of the logarithmic expressions in the
pressure to be 50.7 f 0.1 atm. formula for the fugacity coefficients. A change of the
parameter B according to Eqs. (17) and (18) is sometimes
DISCUsslON necessary to avoid failure in the calculation when the
The algorithm in Fig. 3 has shown the great influence extreme points rather than the mathematical roots are
that the choice of roots in the solution of the cubic used as compressibility factors.
equations of state has on flash calculations. The physical The reason why flash calculations fail at high pressure
interpretation of the number of roots of the equation has been found to be the lack of good initial estimates of
seems to vary in the literature. According to Peng and the phase composition. Attempts have been made to find
Robinson[2], their equation of state yields one or three methods for this estimation, but with poor results
roots depending on the number of phases in the system. because the connections between the phase compositions
The authors experience with the SRK equation of state and the Q and R parameters are too complex. The result
is that it is only at low pressure levels that the function of poor starting values of the phase compositions may be
F(Z) (Eq. 10) is shaped as in Fig. l(a) with three roots that the first estimate of the vapour phase compres-
for both phases. sibility is less than the liquid phase compressibility. The
I 1
366 369
TEMPEFtATURE IKI
Fig. 7. Phase diagramfor test mixtureII (3 components).The curves show vapourfractionsof 0,20,40,60,80 and
100mole %.
254 TRULSGUNDERSEN
iteration then fails with ZLIQ=ZVAP and Ki + 1.0 F total amount of moles in the mixture (flash cal-
(i = 1, NC). This problem was solved by the sequential culations)
technique mentioned in the previous section. With this F parameter in the SRK equation for mixtures (Eq. 8(e))
strategy the proposed algorithm performed properly Fi parameter in the SRK equation for component i (Eq.
within from 0.2 to 2.0 atm from the critical point. An 8(f))
F(Z) SRK equation written as a third degree equation in
alternative method would be the step-wise technique of compressibiity (Eq. 10)
extrapolating the K-values presented by Michelsen[ lo].
f objective function in flash calculations
The importance of a good estimate of the phase com- IPH key for actual phase (vapour or liquid)
positions increases as the equilibrium calulations are Ki equilibrium ratio for component i @q. 3)
carries out in the critical region. The initial estimate of kii binary interaction parameter of the SRK equation
the phase compositions are given as the equilibrium Ni number of moles of component i
compositions at a point in the neighbourhood of the NC number of components
actual point. This neighbouring region gets smaller as one P pressure
approaches the critical region of the phase diagram. Pci critical pressure for component i
parameter of the SRK equation
The system of three components was a lot easier to ! gas constant
handle than the system of eight components. This can be R parameter of the SRK equation
explained by the fact that mixtures of close-boiling T temperature
components give rise to more linear objective functions T,i critical temperature for component i
(Eq. 1) than mixtures of wide-boiling components. Ano- 4 reduced temperature for component i
ther point is the larger amount of numerical roundoffs V amount of vapour in the mixture (moles)
with eight components and the fact that the computer V volume (Eq. 4)
has a limited accuracy. V specific volume (Eqs. 5 and 6)
xi mole fraction of component i in the liquid phase
The proposed algorithm gives numerical results with
mole fraction of component i in the vapour phase
this classical three-component system that are far ; compressibility factor
better than what Boston and Mathias [13] report with the ZLIQ compressibility of the liquid phase
ASPEN program. As is seen from Fig. 7, the present ZVAP compressibility of the vapour phase
approach works well up to 50.5 atm, while the ASPEN zi mole fraction of component i in the mixture
program gives physically unacceptable results for pres-
sures exceeding 45 atm. Greek symbols
At the exact critical point, all flash calculation routines a constant of the SRK and PR equation
fail because all K-values tend to be 1.0. The function fi constant of the SRK and PR equation
y constant of the SRK and PR equation
(Eq. 1) approaches zero in the whole region 0 d 6 s 1. [ vapour to feed ratio (V/F)
The program is therefore not able to predict the vapour- I$ fugacity coefficient
to-feed ratio. How close to the critical point calculations a, constant of the SRK and PR equation
can be performed depends on the chosen algorithm, the fib constant of the SRK and PR equation
numerical accuracy of the computer and, as it is seen, Oi acentric factor for component i
the number of components in the system. Hydrocarbon
gas processing conditions are often close to the critical Subscripts
point, and the high pressure capabilities of flash cal- i loop index and component identifier
culation routines are therefore important. j loop index and component identifier
c critical property
Another interesting aspect is the use of these some- r reduced property
what sophisticated methods for estimating K-values in
flowsheet simulators. In commercial packages the com- Superscripts
pressibility factors and K-values are regarded as inter- L liquid phase
mediate results, and therefore not printed out. The V vapour phase
chemical engineer is therefore not able to verify the
results. If a sequential technique were applied, as des- RElmRENcm
cribed in this paper, the time-consumption would in some 1. G. Soave, Equilibrium constants from a modiied Redlich-
cases be prohibitive. There is, therefore, a need for Kwong equation of state. Chem. Engng Sci. 27, 1197(1972).
2. D. Y. Peng & D. B. Robinson, A new two-constant equation
better methods that are both quick and yet reliable. of state. lnd. Engng Chem., Fundum. 15(l), 59 (1976).
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October 1980. Since that time, Poling kt al.[16] have calculations with equations of state. Trans. I. Chem. E. 56,19
published a paper which is an important contribution to (1978).
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isothermal compressibility, they have arrived at a Chao Seader correlation. Comp. & Chem. Engng 2, I77
method which avoids trivial roots and spurious deriva- (1978).
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hydrocarbon mixtures. A.J.Ch.E.Trans. 38,995 (1942).
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6. H. H. Rachford & J. D. Rice, J. Petrol. Technol., 4: 10,
until the spurious roots are removed and the calculation
sec. 1, p. 19; sec. 2, p. 3 (1952).
can proceed. 7. R. C. Reid, J. M. Prausnitz & T. K. Sherwood, The Proper-
ties of Gases and Liquids, 3rd Ed. McGraw-Hi, New York
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A parameterof the SRK equation (Eq. 8(a)) developed for SRK-equation. Oil & Gas I. pp. 61-64, 27
(1 parameter of the PR equation
Nov. (1978).
B parameter of the SRK equation (Eq. 8(b))
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b parameter of the SRK equation for mixtures (Eq. 8(c))
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bi parameter of the SRK equation for component i (Eq
Des. & Dev. 8, 579 (1%9).
8(d))
Numerical aspects of the implementation of cubic equations of state in flash calculation routines 25s
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