Reducing Energy Consumption, Operation Cost,

Environmental Impact for LPG Separation

Unity, by using Process Energy Integration
Ahmed Ould Brahim, Souad Abderafi

Laboratory for Analysis and Synthesis ofIndustrial Processes LASPI

Mohammadia School ofEngineers (EMI), Ibn Sina, B.P. 765, Agdal , Mohammed V University in Rabat, Morocco

ahmed.ouldbrahimOl@gmail.com / abderafi@emi.ac.ma

Abstract minimize energy consumption, the problem is always posed,

The Liquefied Petroleum Gas (LPG) separation unit is one of
process, in chemical industries that consume great energy. In this
work, Pinch technology for heat recovery is used to minimize the
energy consumption of the LPG separation process, for a
Moroccan oil refinery. This methodology was applied to the study
of the separation of LPG, using the two distillation columns:
recovery and splitter columns. Experimental data required to
follow this method, were obtained from Moroccan oil refinery,
during period of May 2015. To find the optimal energetic
integration, the different calculations were performed by
simulation, using PRO 11 software. Results analyses show that the
integration of three heat exchangers in conventional process
reduces the energy consumption of process, operation cost and
decreases the impact environment.
to achieve separation.
Distillation is the primary separation process used in industrial
chemical processing. While, it has many advantages, the
significant energy requirement is one major drawback which
can significantly intluence overall plant profitability. It is quite
energy intensive and accounts for a large part of industrial
energy consumption [2]. Increasing energy costs deter energy
consumption as do tighter environmental regulations regarding
fossil fuel use, leading to research into new and more efficient
separation methods [3].
The objective of this work is to mmlmlze the energy
consumption of the LPG separation process, for a Moroccan
oil refmery, by using Pinch Technology for heat recovery.

Keywords: Energy consumption; Process energy integration; 11. INDUSTRIAL PROCESS

distillation column; LPG separation
I. INTROD UCTION
The crude oil refming produces different chemicals
components, such Liquefied Petroleum Gas (LPG). LPG, also
known as LPG liquefied propane or simply petroleum gas is a
tlammable mixture of hydrocarbon gases used as fuel in
heating appliances and vehicles. It is used as fuel , especially
for vehicles such as cars and motorcycles, also as an aerosol
propellant and refrigerant to avoid damage to the ozone.
Where specifically used as fuel for vehicles, it is often referred
to as auto gas [1].
The petroleum is a complex mixture of different hydrocarbons
fractions , small amounts of sulphur and trace amounts of
oxygen, nitrogen and metals. Separation is effected by heated
the mixture to an elevated temperature of about 400°C, then
injected into an atmospheric pressure distillation column.
Distillation is the separation of completely miscible mixtures
of liquids according to the difference of the boiling point and
volatility of the components in the mixture. However, the
lighter products, as butane, are obtained at the head of the
colunm and the heavier components such as gasoline,
kerosene and gas oil (diesel oil) remains successively lower
[4]. As for the residue that cannot be distilled, even at very
high temperatures remain at the bottom of the distillation
colunm.

The separation of these products is realized by heating the
mixture to an elevated temperature before introducing it in
distillation colunm. This process is widely used to separate oil
products, but its disadvantage is the high energy consumption.
Despite efforts which were conducted by many researchers to
The LPG separation unit is intended to treat the lighter
fractions of oil and produce propane and butane. This process
is composed of two columns as seen in Figure l. The first
column is the LPG recovery column, possessing 29 theoretical
trays, is fed at tray 11 ; it is operated at 11.7 bar and the LPG

978-1-5090-5713-9/16/$31.00 ©2016 IEEE

can be condensed with cooling water at this press ure [5]. The TABLE TI. PROPERTlES OF LPG

second column is the LPG splitter column processing 32

theoretical trays, is fed at tray 16 and it is operated at 15 bar. Name ofProperty Value for LPG
The charging unities of the LPG recovery and splitter colurnn
Freezing point -187°C
are comprised of Liquid load from LPG Merox and Plat
Specific Gravity 0.588
forming liquid and Gas load. There are two feed streams of
Vapour Pressure at 38°C 1212KPa
LPG, both streams have the same condition of pressure and
Heat Content 50221KJ/KG
temperature that is 11 bar and 101 °C, but different component
purity and mass flow rates. Table 1 contains the feed
cond itions of process. III. METHODOLOGY
TABLE l. FEED C ONDITlONS OF LPG RECOVERY AND SPLITTER In this project, the methodology of energy integration process
COLUMNS
used to saving the energy consumption in the LPG separation
Feed unities, allows us to reduce the energy consumption and
increase energy efficiency weil.
LPG recovery LPG Splitter In distillation process, heat is supplied to the feed heater and
N (kg mo l/h) 548.891 117.27 the reboiler stream and head is cooled in a condenser. Most of
P (bar) 11.7 18.66 the heat supplied to the reboiler in the distillation conventional
T ( 0C) 101 44 method is disposed in the head condenser [7]. The heat
C 4/O.02 integrated in distillation allows the reject heat to be used for
Specification C50vh 10.015 evaporation in the feed of column. The basic principle of this
C3/0.01
method is that the process hot streams exchange a heat with
cold process streams at optimal temperature approach [8] . This
A. Properties 0/ LPG is an economic way of conserving energy when the difference
It is an established fact that the LPG is a mixture of in temperature between the overhead and bottom of the
hydrocarbon gases, which consists predominantly of propane column is quite high in comparing with storage [9] . On the
and butane. Its composition depends majorlyon its sources, other hand, the high capital expenditure needed for heat
treatment principles and the season where it is produced, exchanger make them industrially viable only for high-
transformed into LPG winter recording still contain more capacity end of train (practically binary) separations of
propane, butane contains more than in summer. LPG is substances with similar boiling points, which require minimal
generally odorless, colorless, non-toxic and ready to explode cost [lO]. Self-heat-recuperation (integration energetic)
at a slightly elevated temperature. The particular characteristic technology facilitate s the recirculation of both latent and
pungent odor that is due to the addition of the odorant, such as sensible heat in a process, and helps reduce the energy
ethanethiol. This product is added in other to reduce the risk of requirements of the process using self heat exchangers based
explosion that can occur due to undetected leaks cargo, pipes on energy recuperation [11]. To re-circulate the self heat in the
or tanks. process, the cooling load is recovered by exchanged with the
heating load. As a result, the heat of the process stream is
The properties of LPG are tabulated in Table 2 [6]. GPL circulated perfectly without heat addition, and the energy
calorific value is equal to 94 MJ 1 m 3 (equivalent to 26.1 consumption for the process can be reduced considerably [12].
kWh), which is greater than that of natural gas, 38 MJ 1 m 3
IV. E QUATIONS OF SIMULATION
(equivalents to 10.6 kWh),
Heat exchanger networks are a means of utilising the heat
available in a process by exchanging between hot and cold
~·········· B ··········~

LPG reco\"ry column LP G splitter column

" -------:>
C3 Propane.
~~~~--~ -----E> Stream C3

Air Cooled B eat Exc.banger

C4 Butane

Figure l. Process ofLPG unity

process streams, thereby decreasing energy demand and
therefore utility costs. The process energy integration problem
can be explained as folIows . Given a set of process streams
needing heating and a set of process streams needing cooling,
we want to determine the minimwn required utilities. For each
stream needing heating or cooling, the inlet and outIet
temperatures are known and the product of tlow rate and heat
capacity is known. To determine the minimum required
utilities, we begin with energy balances on the individual hot
stream (HS) and cold stream (CS):
Where, Qc is heat tlow of condenser and QR is heat tlow of
reboiler.
A. Calculation of C02 emissions
In distillation column such as LPG distillation units, C02 is
generated, mainly, from boilers or fumaces [8]. These devices
are used to provide a heat and power to the process by buming
a fuel. The fuel is combusted when mixed with air, producing
only C02, according to following stoichiometric equation:

(1)

(8)
dQes = Qes = Fes Cp,es (Tes,out - T)
dt eS ,in (2)
Where, x and y are the carbon C and hydrogen H, atoms
number, respectively, present in the fuel compositions, and
Where, FHs is the tlow rate (pound per hour) of a hot stream (a
where complete oxidation of carbon is assumed.
stream needing cooling); Fes is the tlow rate (kilogram per The heat and power generating devices used are frred heater
second) of a cold stream (a stream needing heating); Cp is the
(furnace), boiler. This device is source of C02 emissions.
stream heat capacity (kilojoule per kilogram-Celsius); T is the
Typical fuels used in this heating device are light and heavy
temperature (0C) and Q is the energy.
fuel oils, natural gas. In the combustion offuels, air is asswned
to be in excess to ensure complete combustion, so that no
Energy consumption, in each distillation colurnn can be
carbon monoxide is formed. The concentration of C02
achieved by calculation. The material balance, component
emissions, [C02] Emiss (kg/s), is related to the amount of fuel
balance and energy balance for the overall colurnn are [9]:
bumt, Q FUd in a heating device as folIows:
F=D+B (3)
[CO] = (QFuel l(C% la (9)
2 Elil i ss NHV) 100)
FZF =DxD +BxB (4)

Where, a = 3.67 is the ratio of molar masses of C02 and C,

FH F +QR =DH D +BH B +Qe (5) while NHV the net heating value offuel equal to 39,771 kJ/kg,
with a carbon content of Carbon equal to 86.5 % [8].
The material balance in each tray, the energy balance and the
heat quantities in the boiler and in the condenser are obtained The amount of fuel burnt in a fumace can be related to the
by these equations [8]: heat duty required by the process, Q Proc (kW), and the
efficiency ofthe furnace, '17 Fum as follows[9].
Qe = V2 H 2 - (L1 + D)h1 (6)
QF Il e! = Q Proc (10)
QR = VBH B +Bhn -Lnh n (7)
'7 Furn

Through the use of a process simulator, Pro 11 Invensys, for

G -=:> C3 Prop ane
LPG re COHY column H3 +=> ____ --- G -L ___ ~
LPG splitter column I:

Cl

B "~
H eat Exchange r E2 1 C3

I Gaso Line +LPG

(Liq uid + Gas)
Hl
C4 But ane

.+=>
~--------------~~

Figure 2.Proposed process.

simulations, Peng-Robinson equation of state that supports the using the data of Figure 3 and represented in Figure 4. It
widest range of operating conditions and the greatest variety allows us to determine the optimal heat exchanger network
of systems was used to predict the vapor-liquid equilibrium design that minimizes the energy consumption of the LPG
[15]. separation unities.

B. Formulation of operation cost TAßLE TTT. STREAM DATA SUMMARY

The operating cost of the process is calculated as the sum of Stream Type FCp(kw r C) Tin T out
operating costs for the condenser and reboiler of the column (0C) (0C)
plus the operating costs ofthe Air cooled: Feed(Mixer) Cold 46.42 101 129
Gasoline Prod Hot 30.95 142 100
(11) Cold 52
LPG Prod 333.33 55
C3 Propane Hot 40.37 66 42
(12) LPG feed Cold 63.82 44 92
C4 Butane Hot 43.59 97 29
C e = Co;c X Qreb (13)
Staring at the upper pinch temperature of97°C, the energy rate
is assigned a O-kW value. From 100 to 101 °C, the surplus of
v. RESULTS AND DlSCUSSION
433 kW is plotted with a negative slope. The pinch range of
To mmlmlze the size of the column and total energy 97- 100°C is assigned a O-kW value. Starting at the lower
consumption, the integration of LPG recovery column and pinch temperature of 97°C, the interval from 97 to 92°C has
LPG splitter using the heat exchanger network was proposed. a 216 kW deficit enthalpy residual, which is plotted with a
Figure 2 illustrates the three heat exchanger arrangement in positive slope. The interval from 92 to 66°C has a 217 kW
the LPG process, each heat exchanger, is considered the main surplus enthalpy, which is subtracted from (98 kW, 29°C).
fractionators as weil as the prefractionator for the following
column and the air cold for fin stream in this new process.
Simulation of this proposed process was perforrned, using the
equations described above, with respect to the flow of the - - - - - --r---------- 142 T (o e)
distillate and reflux streams of the 1st and 2 nd columns, side
129
tray location and the feed tray location in each column.
Experimental data required for this method were obtained
HI Cl
from LPG separation process in Moroccan oil refinery (Table
1), during period ofMay 2015. The different calculations were 101
performed using PRO 11 software. 100
The simulation was realised by fixing the product recovery 98
and purity of the two options considered (conventional process
and the proposed process) and consumption duty of these two 92
options were investigated and compared. Energy integration
explores the interconnection between the utility heating and C3
67
cooling requirements of a process [12]. These heating and
cooling requirements may be determined as part of the design

1
55
phase of the plant where a heat exchanger network is used to
H3 H2 C2
exchange between hot and cold process streams and unmet 52
demand is met by the utility plant as depicted in Figure 2. 44
Using the stream data given in Table 3 for the proposed 42
process, deterrnine the pinch location and minimum heating
and cooling requirements when using a minimum approach 29
temperature of O°C, also draw the Grand Composite Curve
(GCC). Starting with stream feed 1, it is a cold stream being Figure 3. Temperature interval analysis
heated from 101 ° to 129 °C and then from 101 to 129°C prior
to entering column. The heat exchanger duties, Q are know.

The transfer duties in the heat exchanger network were

determined from the equations 1 and 2 and flow sheet
represented in Figure 3. Using the temperature interval
analysis we can generate the GCc. This curve is constructed
 Table 6 regroups the results obtained and shows the reducing
energy consumption, operating cost and environmental impact,
when the new configuration was adapted.
TABLE VI. ENERGY CONSUMPTION, CONCENTRATlON OF C02 EMISSIONS
AND OPERATING COST FOR CONVENTlONAL AND PROPOSED PROCESS

Conventional Proposed Reducing

Process Process

Energy 8000 6100 1800

consumption (KW)
CO 2 (kg/h) 638.54 486.89 148
Cost ($/h) 680 518.5 162

VI. CONCLUSION
In the present work, Pinch technology for heat recovery is used to
minimize the energy consumption of the LPG separation process, in
Figure 4. Grand composite curve
Moroccan petroleum refinery. New configuration was proposed
and different calculations were performed using PRO 11
The results of performance analysis of conventional process
software, basing on mass, energy and entropy balances. The
and those obtained after integration of three heat exchangers
PR EOS was used to calculate thermodynamic properties of
are presented in Tables 4 and 5, respectively. These results
mixture required for simulation.
show that the new configuration compared to conventional
The results of the studies allowed us to highlight the effect of
one, for LPG separation process gets a better use of energy.
integration of three heat exchangers. These results show the
reduction of energy consumption reduces of process, operation
TABLE IV. P ERFORMANC E OF LPG CONVENTlONAL PROCESS cost and decrease the impact environment, in comparison to
the conventional LPG separation unit.
Stream Recovry Splitter Overall
HX Air Column Column
ACKNOWLEDGEMENTS
Cooled
HXDuty 500 - - 500 The authors gratefully acknowledge support provided by
Qc(KW) - -2900 -200 -3100 Moroccan Petroleum refinery SAMIR (Societe Anonyme
Qr(KW) - 3900 500 4400 Marocaine de l'Industrie du Raffinage).
Energy (KW) 8000

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TABLE V. P ERFORMANC E OF LPG PROCESS AFTER INTEGRA Tl ON
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