Configuring topologically optimum vapor recompressed dividing-wall distillation columns to maximize operating efficiency

For dividing-wall distillation columns(DWDCs) separating a heavy-component dominated and wide boiling-point ternary(HCDWBT) mixture, a significant amount of excessive heat exists inevitably in stripping the heavy-component from the intermediate-component and it can be employed to initiate the development of vapor recompression heat pump(VRHP) assisted DWDC(VRHP-DWDC). Despite dividing wall may locate in the top, middle, and bottom, the optimum VRHP-DWDC is found to involve uniformlytwo VRHP circles. While the first one serves to compress and transform the excessive heat resulted from the separation of the heavy-component from the intermediate-component, the second one to compress and transform the overhead vapor stream of the light-component pre-heated sequentially with the condensate from the first one and the bottom product stream of the heavy-component, both releasing the temperature-elevated latent heat to the pre-fractionator's or common stripping section. The processing of two HCDWBT mixtures of benzene/toluene/o-xylene and n-pentane/n-hexane/n-heptane are selected to assess the derived optimum topological configurations of the VRHP-DWDC and their optimality is confirmed through detailed comparisons with the DWDC and two VRHP-DWDCs involving only one VRHP circle. The proposed strategy helps to tap the full potential of the VRHP-DWDC with considerably alleviated complication in process development.

Reinforced temperature control of a reactive double dividing-wall distillation column

The mass and thermal coupling makes the control of the reactive double dividing-wall distillation column(R-DDWDC) an especially challenging issue with a highly interactive nature. With reference to the separation of an ideal endothermic quaternary reversible reaction with the most unfavorable ranking of relative volatilities(A + B ■ C + D with α_(A)>α_(C)>α_(D)>α_(B)), the operation rationality of the R-DDWDC is studied in this contribution. The four-point single temperature control system leads to great steady-state discrepancies in the compositions of products C and D and the reason stems essentially from the failure in keeping strictly the stoichiometric ratio between reactants A and B. A temperature plus temperature cascade control scheme is then employed to reinforce the stoichiometric ratio control and helps to secure a substantial abatement in the steady-state discrepancies. A temperature difference plus temperature cascade control scheme is finally synthesized and leads even to better performance than the most effective double temperature difference control scheme. These outcomes reveal not only the operation feasibility of the R-DDWDC but also the general significance of the proposed temperature difference plus temperature cascade control scheme to the inferential control of any other complicated distillation columns.

Synthesis and Design of Distillation Columns for Wide-Boiling Binary Mixtures with Vapor Recompression Heat Pumps

The vapor recompression heat pump(VRHP) distillation technology offers significant improvements in energy efficiency for distillation systems with small temperature differences between the top and bottom of the column. However, the separation of wide-boiling binary mixtures leads to substantial temperature differences between the top and bottom of the column. This limits the applicability of conventional VRHP due to high capital costs and strict performance requirements of the compressor. To overcome these challenges and to accommodate compressor operating conditions, a novel synthesis and design method is introduced to integrate VRHPs with wide-boiling binary mixture distillation columns(WBMDCs). This method enables quick determination of an initial configuration for the integrated WBMDC-VRHP system and helps identify the optimum configuration with the minimum total annual cost. Two examples, namely the separation of benzene/toluene and isopropanol/chlorobenzene, are employed to derive optimum configurations of the WBMDC-VRHP and compare them with the WBMDC. A systematic comparison between the WBMDC-VRHP and WBMDC demonstrates the superior steady-state performance and economic efficiency of the WBMDC-VRHP.

Gamma Photon Column Scanning of Prototype and Industrial Distillation Columns

Monte Carlo simulation of gamma photon transport and interaction with the distillation column and its contents was performed in order to predict the effects of gamma photons when they interact with matter. The results of the interaction and transport of gamma photons are presented as energy deposition on the distillation column and its contents. Energy attenuation was more pronounced on the column walls and trays as compared to the region between the trays, where there is mostly vapour space. Gamma column scanning was then used to verify the Monte Carlo simulation results by scanning and investigating the integrity of two laboratory prototype distillation and industrial distillation columns. One of the prototype distillation columns was 1 m tall with four trays and the other one was 1.8 m tall consisting of six trays and a packed bed. Commonly encountered distillation column malfunctions such as collapsed tray, weeping, flooding and foaming were simulated in the two prototype distillation columns and scanned. The industrial distillation column was a 26 m tall benzole prefractionator column, consisting of 60 single pass trays and a diameter of 0.8 m. A 10 mCi 60Co gamma radiation source and NaI(Tl) scintillation detector were used to scan the distillation columns. The results from the two prototypes showed that all the simulated malfunctions were clearly detected except for foaming. The results from industrial distillation column showed that all the trays were in their correct position although tray number 32 could be partially damaged and just below tray 41, the scan revealed that there was a loss of column wall thickness. The obtained density profile for the industrial distillation column showed some small variations from the expected density profile and this was attributed to external features on the distillation column and wind bursts that shifted the source and detector from the chosen scan line orientation.

Shortcut Procedure for Inverted Batch Distillation Column (I) Multicomponent Ideal System

Inverted batch distillation column(stripper) is opposed to a conventional batch distillation col-umn(rectifier). It has a storage vessel at the top and products leave the column at the bottom. The batch stripper is favourable to separate mixtures with a small amount of light components by removing the heavy components as bottom products. In this paper, we are presenting a shortcut procedure based on our earlier work for design and simulation of the inverted batch distillation column, which is equivalent to the Fenske-Underwood-Gilliland procedure for continuous distillation. Given a separation task, we propose to compute the minimum number of stages(Nbmin) and the minimum reboil ratio(Rbmin) required in a batch stripper,which are the stages and reboil ratio required in a hypothetical inverted batch distillation column operating in total reboil ratio or having an infinite number of stages, respectively. Then, it is shown that the performance of inverted batch columns with a finite number of stages and reboil ratios could be correlated in Gilliland coordinates with the minimum stages Nbmin and the minimum reboil ratio Rbmin.

The Design and Control of Distillation Column with Side Reactors for Chlorobenzene Production

The distillation column with side reactors (SRC) can overcome the temperature/pressure mismatch in the traditional reactive distillation, the column operates at temperature/pressure favorable for vapor-liquid separation, while the reactors operate at temperatures/pressures favorable for reaction kinetics. According to the smooth operation and automatic control problem of the distillation column with side reactors (SRC), the design, simulation calculation and dynamic control of the SCR process for chlorobenzene production are discussed in the paper. Firstly, the mechanism models, the integrated structure optimal design and process simulation systems are established, respectively. And then multivariable control schemes are designed, the controllability of SRC process based on the optimal steady-state integrated structure is explored. The dynamic response performances of closed-loop system against several disturbances are discussed to verify the effectiveness of control schemes for the SRC process. The simulating results show that the control structure using conventional control strategies can effectively overcome feeding disturbances in a specific range.

Enhanced temperature difference control of distillation columns based on the averaged absolute variation magnitude

Temperature difference control(TDC)schemes can clearly suppress the adverse influence of pressure variations on product quality control of various distillation columns(DCs)by employing temperature differences(TDs)between the sensitive stage temperature(T_(S))and reference stage temperature(T_(R)),i.e.,T_(S)-T_(R),to infer the controlled product qualities.However,because the TDC scheme has failed to specially take the corresponding relationship between the TD employed in each control loop and the controlled product quality into account,it may suffer from relatively large steady-state errors in the controlled product qualities.To address this problem,an enhanced TDC(ETDC)scheme is proposed in the current article,in which an enhanced TD(ETD),i.e.,T_(S)-α×T_(R),is employed to replace the conventional TD for each control loop.While the locations of the sensitive and reference stages of the ETD are respectively determined according to sensitivity analysis and SVD analysis,the adjusted coefficientαis set to be the ratio between the averaged absolute variation magnitudes(AAVMs)of the T_(S)and T_(R)so that the relationship between the T_(S)and T_(R)can be appropriately coordinated.With reference to the operations of three different distillation systems,i.e.,one conventional DC distilling an ethanol(E)/butanol(B)binary mixture,one conventional DC distilling an E/propanol(P)/B ternary mixture,and one dividing-wall distillation column distilling an E/P/B ternary mixture,the performance of the ETDC scheme is assessed by compared with the conventional TDC scheme and the double TD control(DTDC)scheme.The dynamic simulation results show that the ETDC scheme is better than the conventional TDC scheme with reduced steady-state errors in the controlled product qualities and improved dynamic responses,and is comparable with the DTDC scheme despite the less temperature measurements are employed.

Optimization of the reflux ratio of benzene-toluene stage distillation columns by the Cuckoo algorithm

In this study, an enthalpy-concentration method was applied in order to model a steady state continuous benzene-toluene mixture distillation column. For a distillation tower such as the benzene- toluene splitter, there are relatively few degrees of freedom that can be manipulated in order to minimize the total annualized cost. The reflux ratio can influence the steady-state operating point and therefore influence the total annualized cost. The trade-offs between reflux ratios and total annualized cost were discussed. The Cuckoo optimization algorithm was applied to obtain a correlation for the optimum value of the reflux ratio as a power function of the economic parameters of energy price and capital cost. The results show that, at low energy price or high capital cost, the optimum reflux factor is high.

Vapor recompressed dividing-wall distillation columns:Structure and performance

Due to the topological structure of double columns and multiple separating sections in dividing-wall distillation columns(DWDCs),the development of vapor recompressed dividing-wall distillation columns(DWDC-VRHPs)represents a challenging issue with great complexities and tediousness.For the separations of light-component dominated and wide boiling-point ternary mixtures,because the purification of the light-component from the intermediate-and heavy-components incurs the primary energy dissipation,the application of vapor recompressed heat pumps(VRHP)should be aimed to reduce the irreversibility and this leads to the generation of the optimum topological structures of the DWDC-VRHPs,i.e.,a DWDC plus a two-stage VRHP.The first-stage VRHP is to preheat feed,not only taking the advantages of the small temperature elevation available but also favoring the mass transfer between the vapor and liquid phases through feed splitting.The second-stage VRHP is to reduce further separation irreversibility.The philosophy can be applied to any DWDCs no matter where the dividing wall locates.Two case studies on the separations of ternary mixtures of benzene,toluene,and o-xylene and n-pentane,n-hexane,and n-heptane demonstrate the economic optimality of the proposed DWDC-VRHPs and reveal the inherent interplay between internal and external process integration.

Troubleshooting Distillation Column by Gamma Ray Scanning Technique

A digitally controlled three-dimensional gamma-scanning apparatuswas developed and used to trou- bleshoot distillation column is thepresent investigation. In a 140 mm (ID) model column, variousmalfunctional phenomena, both rate and process related conditions andstructural problems, which may be frequently encountered in theoperation of tray and packing columns, were experimentally simulatedand tested with the developed scan- ning system. The experimentalresults showed that the scanning spectra can fairly reflect thesimulated phenomena.

Control structure comparison for three-product Petlyuk column

The focus of this paper is to investigate different control structures(single-loop PI control) for a dividing wall(Petlyuk) column for separating ethanol, n-propanol and n-butanol. Four control structures are studied. All the results are simulations based on Aspen Plus. Control structure 1(CS1) is stabilizing control structure with only temperature controllers. CS2, CS3 and CS4, containing also composition controllers, are introduced to reduce the steady state composition deviations. CS2 adds a distillate composition controller(CCDB) on top of CS1. CS3 is much more complicated with three temperature-composition cascade controllers and in addition a selector to the reboiler duty to control the maximum controller output of light impurity composition control in side stream and bottom impurity control in the prefractionator. CS4 adds another high selector to control the light impurity in the sidestream. Surprisingly, when considering the dynamic and even steady state performance of the proposed control structures, CS1 proves to be the best control structure to handle feed disturbances inserted into the three-product Petlyuk column.

Active set truncated-Newton algorithm for simultaneous optimization of distillation column

An active set truncated-Newton algorithm (ASTNA) is proposed to solve the large-scale bound constrained sub-problems. The global convergence of the algorithm is obtained and two groups of numerical experiments are made for the various large-scale problems of varying size. The comparison results between ASTNA and the subspace limited memory quasi-Newton algorithm and between the modified augmented Lagrange multiplier methods combined with ASTNA and the modified barrier function method show the stability and effectiveness of ASTNA for simultaneous optimization of distillation column.

The Analysis of Distillation Tray Column Efficiency by Fluid Dynamics and Mass Transfer Computation

It has long been found that the flow pattern of the liquid phase on distillation tray is of great importance on distillation process performance. But until now, there was very few published work on quantitative investigation of this subject. By combining the computational fluid dynamics (CFD) with the mass transfer equation, a theoretical model is proposed for predicting the details of velocity and concentration distributions as well as the tray efficiency of distillation tray column. Using the proposed model, four different cases corresponding to different assumptions of liquid and vapor flowing condition for a distillation tray column were investigated. In Case I, the distributions of velocity and concentration of the incoming liquid from the downcomer and the uprising vapor from the underneath tray spacing are uniform. In Case n, the distribution of the incoming liquid is non-uniform but the uprising vapor is uniform. In Case HI, the distribution of the incoming liquid is uniform but the uprising vapor is non-uniform. In Case IV, the distributions of both the incoming liquid and the uprising vapor are non-uniform. The details of velocity and concentration distributions on a multiple sieve tray distillation column in four different cases were simulated using the proposed model. It is found that the shape of the simulated concentration profiles of vapor and the liquid is quite different from case to case. The computed results also show that the tray efficiency is highly reduced by the maldistribution of velocity and concentration of the incoming liquid and uprising vapor. The tray efficiency for Case I is higher than Case Ⅱ or Case Ⅲ, and that for Case Ⅳ is the lowest. It also reveals that the accumulated effect of maldistribution becomes more pronounced when the number of column trays increased. The present study demonstrates that the use of computational method to predict the mass transfer efficiency for the tray column, especially for the large one, is feasible.

Heat Transfer Investigation and Modeling of Heat Integrated Distillation Column

The high degree of reversibility of heat integrated distillation column(HIDiC) has been thermodynamically interpreted by the entropy method. In this paper, a heat transfer model and a more universal method were proposed, through which the overall heat transfer coefficient at different height of column under different operating conditions could be obtained before the experiment. Then the separation of a binary ethanol-water system was carried out experimentally as a case study to verify the heat transfer model and the aforementioned calculation method. The close results between the calculation, the simulation, and the experiments suggested that the proposed model and the calculation method in this paper were accurate and applicable. Meanwhile, it was demonstrated that the HIDiC shows obvious effect of reducing entropy increase and improving thermodynamic efficiency as compared to conventional distillation column.

MPC of distillation column with side reactors for methyl acetate

This paper focuses on the dynamic control of distillation column with side reactors(SRC) for methyl acetate production. To obtain the optimum integrated structure and steady state simulation, the systematic design approach based on the concept of independent reaction amount is applied to the process of SRC for methyl acetate production. In addition to the basic control loops, multi-variable model predictive control modular with methyl acetate concentration and temperature of sensitive plate is designed. Then, based on process simulation software Aspen Plus, dynamic simulation of SRC for methyl acetate production is used to verify the effectiveness of the control scheme.

Application of the dividing wall column to olefin separation in fluidization methanol to propylene(FMTP) process

Dividing wall column(DWC)is shown to be energy efficient compared to conventional column sequence for multi components separation,which is used for olefin separation in fluidization methanol to propylene process in the present work.Detailed design for pilot DWC was performed and five control structures,i.e.composition control(CC),temperature control(TC),composition-temperature control(CC-TC),temperature difference control(TDC),double temperature difference control(DTDC)were proposed to circumvent feed disturbance.Sensitivity analysis and singular value decomposition(SVD)were used as criterion to select the controlled temperature locations in TC,CC-TC,TDC and DTDC control loops.The steady simulation result demonstrates that 25.7% and 30.2% duty can be saved for condenser and reboiler by substituting conventional column sequence with DWC,respectively.As for control structure selection,TC and TDC perform better than other three control schemes with smaller maximum deviation and shorter settling time.

Methodology for Design of Reactive Distillation Column and Kinetics for Isoamylene Etherification Catalysed by Amberlyst 35

Isoamylene from the Fischer-Tropsch syncrude can be transformed to valuable fuel oxygenate additives through an equilibrium limited etherification reaction with methanol. A reactive distillation process is established to increase isoamylene conversion. Facing the challenge of improving product purity at the same time, an equilibrium stage model based design methodology is proposed and illustrated step-by-step for converting the Fischer-Tropsch C_5 olefins to tert-amyl methyl ether(TAME) process by using Aspen Plus. Under the guide of the proposed methodology, the design leads to a TAME product purity of higher than 95% and an isoamylene conversion of higher than 90%. The etherification kinetics over Amberlyst 35 is also studied within a temperature range of 60 ℃ to 75 ℃ to shed more light on the feasibility of process development. The methodology provides an effective reactive distillation column design to achieve the target reactant conversion and product purity simultaneously.

Comparative Study of Different Decoupling Schemes for TITO Binary Distillation Column via PI Controller

This paper presents a comparative study of different decoupling control schemes for a two-input, two-output(TITO) binary distillation column via proportional-integral(PI)controller. The key idea behind this paper is designing two novel fuzzy decoupling schemes that depend on human knowledge,instead of the system mathematical model used in conventional decoupling schemes. Based on conventional and inverted decoupling schemes, fuzzy and inverted fuzzy decoupling schemes are developed. The control effect is compared using simulation results for the proposed two schemes with conventional decoupling and inverted decoupling. The proposed fuzzy decoupling schemes are easy to realize and simple to design, besides they have a good decoupling capability. Two methods are used to prove asymptotic stability of each loop and the entire closed-loop system by applying the proposed fuzzy decoupling-based PI controller.The Wood and Berry model of a binary distillation column is used to illustrate the applicability of the proposed schemes.

A Multi-Agent Immune Network Algorithm and Its Application to Murphree Efficiency Determination for the Distillation Column

Artificial Immune Network （aiNet） algorithms have become popular for global optimization in many modem industrial applications. However, high-dimensional systems using such models suffer from a potential premature convergence problem. In the existing aiNet algorithms, the premature convergence problem can be avoided by implementing various clonal selection methods, such as immune suppression and mutation approaches, both for single population and multi-population cases. This paper presents a new Multi-Agent Artificial Immune Network （Ma-aiNet） algorithm, which combines immune mechanics and multiagent technology, to overcome the premature convergence problem in high-dimensional systems and to efficiently use the agent ability of sensing and acting on the environment. Ma-aiNet integrates global and local search algorithms. The perform- ance of the proposed method is evaluated using 10 benchmark problems, and the results are compared with other well-known intelligent algorithms. The study demonstrates that Ma-aiNet outperforms other algorithms tested. Ma-aiNet is also used to determine the Murphree efficiency of a distillation column with satisfactory results.

Unique influences of reboiler inventory control on the operation of totally reboiled reactive distillation columns

In this work,the dynamics and operation of the totally reboiled reactive distillation columns are visualized in terms of transfer function based process models.This kind of processes is found to be characterized by underdamped step responses due to the special topological configuration and the intricate interplay between the reaction operation and the separation operation involved.The under-dampness can be substantially alleviated through the tight inventory control of bottom reboiler and this presents beneficial effects to process dynamics and operation.Two totally reboiled reactive distillation columns,separating,respectively,a hypothetical synthesis reaction from reactants A and B to product C,and a real decomposition reaction from 1,4-butanediol to tetrahydrofuran and water,are employed to demonstrate these uncommon behaviors.The results obtained give full support to the above qualitative interpretation.Despite the strong influences of reaction kinetics and thermodynamic properties of the reacting mixtures,the totally reboiled reactive distillation columns are generally considered to present such unique behaviors and require tight inventory control of bottom reboiler to facilitate their control system development.