09highly Coupled Dist Syst

Advanced Distillation with Aspen Plus
Highly Coupled Distillation Systems

2002 AspenTech. All Rights Reserved.
Lesson Objectives
Understand alternative strategies for modeling Highly Coupled Distillation Systems in Aspen Plus.
10 1
Aspen Technology, Inc.
Modeling Distillation Systems (1)

Examples of highly coupled distillation systems include: Azeotropic distillation Ethanol dehydration using benzene or cylcohexane IPA dehydration using benzene Acetic acid dehydration using butyl-acetate Extractive distillation C4 extraction using DMF or acetonitrile Separation of toluene and MCH using phenol
Modeling Distillation Systems (2)

Ethylene plant quench section Quench tower + primary fractionator + fuel oil stripper Absorber/stripper systems (for acid gas removal) Rectisol process (methanol)
Amine processes (MEA, DEA)
Liquid-liquid extraction/stripper BTX extraction using Sulfolane or ethylene glycol
10 2
Approaches
Two approaches for modeling these systems: 1. Model them as several interconnected RadFrac blocks (The Flowsheet approach) 2. Use MultiFrac block (The Simultaneous Approach applicable only to selected problems)
Considerations for the Flowsheet Approach

Flowsheet convergence is greatly affected by:
Solvent makeup using Fortran blocks or Balance blocks Choice of tear streams Choice of recycling convergence methods Choice of column specifications Tolerance balancing Sequencing
10 3
Extractive Distillation Case Study

Separation of toluene and methyl-cyclohexane (MCH)
Uses phenol as the solvent Uses a flowsheet that consists of an extractive distillation column and a regeneration column Modeled with the UNIFAC Property Method to represent the Vapor-Liquid Equilibrium
Extractive Distillation Base Case (1)

EXT -COL
7 14
HOT -FEED
MCH-PROD
Pressure Drop Per Stage 0.2 psi Total Condenser Distillate Rate 200 lbmol/hr Reflux Ratio 8
COL-BTMS TOL -PROD
22 Temp 220 Pres 20

FEED HEATER Temp 200 Pres 20 Mole Flow MCH 200 lbmol/hr Toluene 200 lbmol/hr REGEN
10
Temp 200 20 Pres 20 Mole Flow Toluene 12 lbmol/hr Phenol 1188 lbmol/hr
SOLVENT
Filename: EX9A-EXTDIST1.BKP
10 4

Converging tear streams: SOLVENT * WARNING CONVERGENCE BLOCK $OLVER01 NOT CONVERGED IN 30 ITERATIONS 3 vars not converged, Max Err/Tol ** 0.52165E+02
ERROR Convergence block $OLVER01 did not converge normally in the final pass

COL-BTMS FEED HOT-FEED MCH-PROD SOLVENT TOL-PROD 311.8 77.0 220.0 219.3 355.9 232.9 20.20 20.00 20.00 16.00 19.80 16.00 0 0 0 0 0 0 1399.999 400.000 400.000 200.000 1199.999 200.000 131351.120 38065.736 38065.736 19530.077 112815.462 18536.285 2342.544 751.920 828.128 445.729 1980.486 386.440 -59.834 -15.234 -12.690 -13.427 -58.950 0.799 17.886 243.287 1138.825 200.000 200.000 0.000 200.000 200.000 0.000 182.114 17.576 0.309 0.000 60.863 1139.135 17.885 182.106 0.008
Temperature F Pressure psi Vapor Frac Mole Flow lbmol/hr Mass Flow lb/hr Volume Flow cuft/hr Enthalpy MMBtu/hr Mole Flow lbmol/hr MCH TOLUENE PHENOL
10 5
Extractive Distillation Add Makeup (1)

RECYCLE EXT -COL MIXER MAKEUP SOLVENT MCH-PROD
Temp 220 Pres 20 Mole Flow Phenol 1 lbmol/hr
Pres 20
FEED HEATER
HOT -FEED COL-BTMS
TOL -PROD
REGEN
10 6
10 7

> Loop $OLVER01 Method: WEGSTEIN Iteration 30 Converging tear streams: SOLVENT * WARNING CONVERGENCE BLOCK $OLVER01 NOT CONVERGED IN 30 ITERATIONS 3 vars not converged, Max Err/Tol -0.59837E+02 ** ERROR BLOCK MIXER IS NOT IN MASS BALANCE: MASS INLET FLOW = 0.14802432E+02, MASS OUTLET FLOW = 0.14798550E+02 RELATIVE DIFFERENCE = 0.26230909E-03 MAY BE DUE TO A TEAR STREAM OR A STREAM FLOW MAY HAVE BEEN CHANGED BY A FORTRAN, TRANSFER, OR BALANCE BLOCK AFTER THE BLOCK HAD BEEN EXECUTED. ** ERROR Convergence block $OLVER01 did not converge normally in the final pass

Temperature F Pressure psi Vapor Frac Mole Flow lbmol/hr Mass Flow lb/hr Volume Flow cuft/hr Enthalpy MMBtu/hr Mole Flow lbmol/hr MCH TOLUENE PHENOL COL-BTMS FEED HOT-FEED MAKEUP MCH-PROD RECYCLE SOLVENT TOL-PROD 313.1 77.0 220.0 220.0 219.3 356.6 356.5 232.9 20.20 20.00 20.00 20.00 16.00 19.80 20.00 16.00 0 0 0 0 0.00043561 0 0 0 1449.260 400.000 400.000 0.334 200.000 1249.260 1249.260 200.000 135987.288 38065.736 38065.736 31.468 19529.235 117450.128 117450.788 18537.160 2422.828 751.920 828.128 0.503 483.753 2061.649 2061.606 386.487 -62.425 -15.234 -12.690 -0.020 -13.414 -61.377 -61.015 0.787 18.031 243.555 1187.674 200.000 200.000 0.000 200.000 200.000 0.000 0.000 0.000 0.334 181.970 17.704 0.326 0.001 61.593 1187.666 0.000 61.259 1188.000 18.030 181.962 0.008
10 8
Extractive Distillation Redundant Specs

Distillate rate is specified for both columns. Instead specify a bottoms rate of 1200 lbmol/hr for the REGEN column.
> Loop $OLVER01 Method: WEGSTEIN Converging tear streams: SOLVENT # Converged Max Err/Tol
*** MASS AND ENERGY BALANCE *** OUT 200.000 200.000 0.420749 400.421 38105.3 -0.126200E+08 R ELATIVE DIFF. -0.305866E-10 0.155813E-06 0.000000E+00 0.778092E-07 0.753368E-07 -0.172965
Iteration 0.25089E-01
IN CONVENTIONAL COMPONENTS (LBMOL/HR) MCH 200.000 TOLUENE 200.000 PHENOL 0.420749 TOTAL BALANCE MOLE(LBMOL/HR) 400.421 MASS(LB/HR ) 38105.3 ENTHALPY(BTU/HR
-0.152594E+08
IPA Dehydration Base Case (1)

BENZ-PHS
DECANTER
MIXER AZ-OVHD MAKEUP REFLUX STRPOVHD H2O-PHS STRIPPER
AZEOCOL STRPBTMS FEED IPAPROD
Filename: EX9B-IPADEHY1.BKP
10 9
10 10
10 11

Loosen Tear Stream Convergence Tolerance:

Increase Tear stream iterations:
10 12

> Loop CVBLK # Converged * WARNING Method: WEGSTEIN Max Err/Tol Iteration STRPOVHD -0.87154E+00 39
Converging tear streams: AZ-OVHD
BLOCK STRIPPER IS NOT IN MASS BALANCE: MASS INLET FLOW = 0.92748289E+00, MASS OUTLET FLOW = 0.92783251E+00 RELATIVE DIFFERENCE = 0.37695355E-03 IMBALANCE IS DUE TO A LOOSE TEAR TOLERANCE STREAM STRPOVHD TOLERANCE = 0.10000000E-02
IPA Dehydration Improve Convergence

Use Broyden Convergence Method Tighten the tolerance of the tear streams to 0.0001
> Loop CVBLK Method: BROYDEN Converging tear streams: AZ-OVHD # Converged Max Err/Tol Iteration 8 STRPOVHD -0.11036E+00
Filename: EX9B -IPADEHY2.BKP

10 13
IPA Dehydration Tear Stream Selection

BENZ-PHS DECANTER
MIXER MAKEUP MIXOVHDS REFLUX AZ-OVHD MIXOVHD STRPOVHD H2O-PHS
STRIPPER AZEOCOL FEED
IPAPROD STRPBTMS
Filename: EX9B-IPADEHY3.BKP
IPA Dehydration - Tear Stream Selection

Select MIXOVHDS as the Tear stream to converge.
> Loop CVBLK
Method: BROYDEN
Iteration 0.81613E-01
Converging tear streams: MIXOVHDS # Converged Max Err/Tol
10 14
Ethylene Plant Quench Section

The following table summarizes a typical configuration for an ethylene plant quench section: ... Number of components 28 real components 8 pseudocomponents ... Quench tower 4 theoretical stages ... Primary fractionator 7 theoretical stages 1 pumparound ... Fuel oil stripper 3 theoretical stages ...
Ethylene Plant Quench Section Approach

Flowsheet section approach
Model the quench tower with RadFrac Model the primary fractionator and fuel oil stripper with
MultiFrac Solve a recycle stream via iteration Provide recycle estimates
Simultaneous approach
Use the MultiFrac block to solve all units and recycle
simultaneously Recycle estimates are not required
10 15
Flowsheet Approach
Quench Tower QW1 QW2
1 2 3 4
QTOVHD
Decanter WATER HC HPHC QTBTMS PFOVHD Primary Fractionator

1 2 3 4 5 6 7 1
REFLUX GASOLINE
FEED
PFBTMS
Stripper
Filename: EX9C-QUENCH.BKP
FOSTM
FO
Simultaneous Approach with MultiFrac (1)

QTOVHD
QT-PFR WATER QW1 QW2 FOSTM GASOLINE
FEED PFBTMS
Filename: EX9C-QUENCHMULTI.BKP
10 16
10 17
10 18
Ethylene Plant Quench Section Results

Solution Method Performance Measure Flowsheet MultiFrac Recycle estimates Good None Number of recycle iterations 21 - Recycle convergence 1E-4 -tolerance CPU seconds (PII-266) 60 20 Maximum relative 3E-4 1E-16 mass balance error
10 19

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09highly Coupled Dist Syst

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Advanced Distillation with Aspen Plus

Highly Coupled Distillation Systems

Highly Coupled Distillation Systems

2002 AspenTech. All Rights Reserved.

2002 AspenTech. All Rights Reserved.

2002 AspenTech. All Rights Reserved.

Aspen Technology, Inc.

Advanced Distillation with Aspen Plus

Highly Coupled Distillation Systems

Modeling Distillation Systems (1)

2002 AspenTech. All Rights Reserved.

Modeling Distillation Systems (2)

Liquid-liquid extraction/stripper BTX extraction using Sulfolane or ethylene glycol

2002 AspenTech. All Rights Reserved.

2002 AspenTech. All Rights Reserved.

Aspen Technology, Inc.

Advanced Distillation with Aspen Plus

Highly Coupled Distillation Systems

2002 AspenTech. All Rights Reserved.

Considerations for the Flowsheet Approach

2002 AspenTech. All Rights Reserved.

2002 AspenTech. All Rights Reserved.

Aspen Technology, Inc.

Advanced Distillation with Aspen Plus

Highly Coupled Distillation Systems

Extractive Distillation Case Study

2002 AspenTech. All Rights Reserved.

Extractive Distillation Base Case (1)

22 Temp 220 Pres 20

2002 AspenTech. All Rights Reserved.

Aspen Technology, Inc.

Advanced Distillation with Aspen Plus

Highly Coupled Distillation Systems

Extractive Distillation Base Case (2)

2002 AspenTech. All Rights Reserved.

Extractive Distillation Base Case (3)

2002 AspenTech. All Rights Reserved.

2002 AspenTech. All Rights Reserved.

Aspen Technology, Inc.

Advanced Distillation with Aspen Plus

Highly Coupled Distillation Systems

Extractive Distillation Add Makeup (1)

Temp 220 Pres 20 Mole Flow Phenol 1 lbmol/hr

HOT -FEED COL-BTMS

Extractive Distillation Add Makeup (2)

2002 AspenTech. All Rights Reserved.

2002 AspenTech. All Rights Reserved.

Aspen Technology, Inc.

Advanced Distillation with Aspen Plus

Highly Coupled Distillation Systems

Extractive Distillation Add Makeup (3)

2002 AspenTech. All Rights Reserved.

Extractive Distillation Add Makeup (4)

2002 AspenTech. All Rights Reserved.

2002 AspenTech. All Rights Reserved.

Aspen Technology, Inc.

Advanced Distillation with Aspen Plus

Highly Coupled Distillation Systems

Extractive Distillation Add Makeup (5)

2002 AspenTech. All Rights Reserved.

Extractive Distillation Add Makeup (6)

2002 AspenTech. All Rights Reserved.