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Low Energy Distillation Schemes

G.T.Polley
Pinchtechnology.com

Having looked at the thermodynamics of individual separations (Jan. 2002 and Feb.
2002) we now turn our attention to how the more energy efficient schemes that
require more than one separation can be identified. We start by considering nonintegrated systems.
Multi-Component Systems: Non-integrated Distillation Schemes
Consider the use of a distillation scheme for the separation of a four component
mixture into its constituent parts. The number of ways in which this can be
accomplished is shown in Figure 1. Each scheme requires three distillation columns.
The terms in brackets indicate the components in the bottom product of each
distillation column.
There are five possible schemes. It can be seen that these schemes consist of
different combinations of nine individual separations.
Similar trees can be developed for other problem sizes.
The size of various problems are listed in Table 1.
These trees only have to be developed once for each problem size. They can then
be used in the solution of any problem having that size.

Size

3
4
5
6
7

Number of
Sepns
2
3
4
5
6

Number of
Possible
Schemes
2
5
14
42
132

Number of
Possible
Components
4
9
20
35
56

Table 1. Effect of Problem Size on Complexity

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B[CD]

C[D]

BC[D]

B[D]

A[BCD]

A[B]
ABCD

AB[CD]
C[D]

Figure 1. Schemes for Separating Four Components

A[BC]

B[D]

ABC[D]
AB[C]

A[B]

Figure 1

The best non-integrated scheme can be identified by evaluating the cost of each
possible separation and determining the overall cost of each scheme by summing
costs along each individual branch of the tree.
Given the speed and power of modern computers and the availability of shortcut
design methods for distillation columns, such a procedure would not be excessively
time consuming.
Thermodynamic Analysis: Heat Load Table
The information coming from the analysis of the possible separations includes values
for the dew and bubble point temperatures for both the reboilers and the condensers
(i.e. the temperature spans over which heat is demanded and made available) and
the reboiler and condenser heat loads. This information can be displayed, reboilers
side by side with condensers in a simple table (see Table 2).
If the information is listed in order of temperature, we see where heat from a
condenser can be used to drive a reboiler. A load on the right hand side of the table
appears above one on the left hand side of the table.
We have a tool for determining the scope for energy saving through internal
integration of the columns. For instance, in the example shown in Table 3, we see
that only the reboiler used for the A/B split is at a low enough temperature to be
integrated with overheads from another column (opportunities associated with
column pressure manipulation will be considered later). The maximum heat saving
from internal integration is 3.2 MW.

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Integration of Isobaric Multi-Component Systems

The derivation of a table for each separation scheme would be tedious and time
consuming. What if we developed a table containing all of the possible separations.
The result may be that given in Table 3.
Now, our objective is to identify opportunities for using condensers to drive reboilers.
So, working down the table, the part that is of particular interest is that between the
first appearance of a condenser load (on the right hand side of the table) and the last
appearance of reboiler load (on the left hand side).
There are two problems to be overcome before we can use this information. The first,
is that not all condenser/reboiler matches are feasible. The second, is that we havent
identified opportunities for using one condenser load to drive more than one reboiler.
The first of these problems can be overcome by drawing up a list of mutual exclusive
matches and a list of possible combinations. Like the separation trees, such lists only
have to be drawn up once (see Rajah & Polley, 1995). For problem involving up to
five components the lists presented in Table 4 apply. We can use these lists in
combination with the Heat Load Table to identify feasible matches.
The second problem, that of identify multiple integration opportunities, can be solved
by using cumulative heat loads rather than single operation heat loads. For
instance, consider the reboiler on the B/C split, we see from the combination list that
such a split can occur in a scheme that also uses an A/BC split lower down the
temperature scale. The B/C reboiler has a load of 24.3 MW and the A/BC reboiler
has a load of 5.3 MW. This gives a cumulative load of 29.6 MW. A suitable
condenser placed higher on the temperature scale and having a heat load in excess
of this value could be used to drive either or both of these reboilers.

Reboiler
s
Split
ABCD/E
C/D
AB/CD

A/B

Condrs
t - dew
106
97.6
75.5

t - bub
106
97.6
81.2

49.9

49.9

Load
63.3
12.3
27.2

Split

t dew

t bub

Load

ABCD/E
C/D

60.9
62.7

72.3
62.7

62.3
12.6

AB/CD
A/B

37.5
12.4

37.5
12.4

26.7
3.2

3.2

Table 2. Simple Heat Load Table

Condensers can be treated in a similar manner. For instance, a condenser on a

C/DE split could appear in the same scheme as one on a D/E split (which appears
higher in the temperature scale). So, the cumulative load available at this
temperature is the sum of these two loads.

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Building these cumulative loads into the heat load table the Cumulative Heat Load
Table is developed (Table 5).

Reboilers
Split
ABCD/E
BCD/E
CD/E
D/E
ABC/DE
BC/DE
C/DE
ABC/D
C/D

t dew
106
106
106
106
103
103
103
97.6
97.6

AB/CDE
B/CDE
A/BCDE
AB/CD
B/CD

87.2
87.2
79.4
75.5
75.5

30.6
30.5
7.6
27.2
27.2

A/BCD

67.9

6.3

AB/C
B/C

62.7
62.7

24.3
24.3

A/BC

A/B

t bub
106
106
106
106
103
103
103
97.6
97.6

57.5

49.9

58.3

49.9

Load
63.3
63.5
63.8
63.5
21.5
20.5
17.5
16.1
12.6

Condrs
Spli

t dew

t bub

Load

D/E

97.6

97.6

63.4

CD/E

75.5

81.2

63.5

BCD/E

67.9

75.1

62.9

C/DE
C/D
ABCD/E

62.7
62.7
60.9

62.7
62.7
72.3

17.5
12.6
62.3

BC/DE
BC/D
ABC/D
ABC/DE

57.5
57.5
50.1
50.1

58.3
58.3
54.9
54.9

19.7
16.1
16.5
20.2

B/CDE
B/CD
B/C
AB/CDE
AB/CD
AB/C
A/BCDE
A/BCD
A/BC
A/B

49.9
49.9
49.9
37.5
37.5
12.4
12.4
12.4
12.4
12.4

49.9
49.9
49.9
43.0
43.0
12.4
12.4
12.4
12.4
12.4

30.1
26.9
24.3
20.2
26.7
24.2
7.6
6.3
5.3
3.2

5.3

3.2

Table 3. Heat Load Table Containing all Possible Components

Now lets examine this table in more detail. The D/E condenser operates at the
highest temperature. So, we start by examining how this unit can be integrated.
Immediately below this condenser is the AB/CDE reboiler. The D/E split can occur in
the same scheme as the AB/CDE split. So, the match is feasible. We see from the
cumulative load that the A/B reboiler can be included in the scheme.

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Moving down the table, the next reboiler encountered is on the B/CDE spli. Again this
is a feasible match. The cumulative load indicates that are no other suitable reboilers
exist in a scheme using these two splits.
The next reboiler encountered is that on the A/BCDE split. The cumulative load
information shows two options for a second integration (a B/CD or a B/C split).
Moving yet further down the table we encounter the AB/CD, B/CD and A/BCD
reboilers. None of these splits can be present in a scheme having a D/E split.
Finally, we see opportunities to link the D/E condenser with either the AB/C reboiler
or the B/C reboiler.
Having identified schemes involving the D/E condenser, we can move to that having
the next highest temperature. This is the one on the CD/E split. When we examine
the reboilers positioned below this unit we don not finad ant reboilers that can appear
in the same scheme.
Moving on to the condenser on the BCD/E split. We find only the reboiler on the B/c
split to be a feasible candidate.
We also find that the other condensers present little opportunity for integration.
In summary, examination of the Table shows the following integration opportunities:
1. Condenser D/E with reboilers on AB/CDE (30.6) and A/B (3.2) saving 33.8 MW
2. Condenser D/E with reboiler on B/CDE saving 30.5 MW
3. Condenser D/E with reboilers on A/BCDE (7.6) and/or B/C (24.3) with dual
integration yielding a saving of 31.9 MW
4. Condenser BCD/E with B/C (24.3) and A/BC (5.3) saving 29.6 MW
Rather than examine fourteen possible schemes (the non-integrated case) we only
need examine four.
Procedure
In summary, the procedure developed above is:
1.
2.
3.
4.
5.

Identify the possible schemes

Analyse each possible individual separation
Develop the Heat Load Table containing all options
Identify thermal integration options
Evaluate identified integrated schemes

General Observations
Consider the order in which the condenser and reboilers appear in there respective
lists. The letters used to designate the components are chosen in order of
component volatility. A being the lightest component. E the heaviest. Since, it is the
dew and bubble point temperatures which are important, this order can be expected
to be the same for all problems.
The divisions between the lists could change. For instance, the CD/E condenser in
one problem could be at higher temperature than the B/CD reboiler. However,
moving upwards, this condenser cannot occur in any scheme below the A/BCDE
split.
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In the case of the BCD/E condenser, this cannot be used in any additional scheme
below the B/CD reboiler.
The example being considered is that set by Heaven (1969) and used in many
papers on separation scheme synthesis. The details of the separation are given in
Table 6. Examination of this table shows that streams D and E make up more than
half of the initial feed stock. It is not surprising that the D/E split should have such a
high heat load. As the make-up of the feed shifts towards the lighter components the
heat available from the D/E condenser falls and importance of other units will
increase.
Bringing these observations together, we can draw the following conclusions:

the schemes identified for this problem are general

as the feed composition shifts towards the lighter components the
condenser on the BCD/E split becomes more important
another scheme that could possibly be important is one in which the
relative positions of the BCD/E condenser and the B/CD reboiler allows
integration

So, for isobaric schemes, the designer does not need to evaluate all of the possible
component separations and produce the Heat Load Table! The designer can start by
determining the loads on the D/E and BCD/E condensers. If that on the BCD/E
condenser is the highest, the scheme involving that condenser should be evaluated.
Opportunities of linking with B/CD reboiler should also be examined. If the load on
the D/E condenser is the highest, the schemes identified above should be evaluated.
Non-isobaric Schemes
The scope for integration, and hence energy needs, can be changed by operating
individual separations at different pressures. Unfortunately, in addition to changing
the temperature levels of individual condensers and reboilers, changes in pressure
also result in changes in column heat loads. Andrecovich & Westerberg [1985] found
that both column heat duty and the difference between reboiler and condenser
temperatures increased with increasing pressure. Both quantities were found to
exhibit approximately linear changes with respect to temperature level. Given this
finding we do not need to re-evaluate the individual separations over a range of
pressures. We can determine loads and temperatures at the extremities of
permissible pressure range and then use interpolation.
However, we do not to do this for each and every possible separation. We can
identify the significant potential changes using the Heat Load Table.
Pressure changes are only justified if they result in energy savings that are greater
than those identified for isobaric operation. The first key point in the isobaric picture is
the temperature of the D/E condenser. We can improve upon the recovery from this
stream if we move a valid reboiler below this level or shift the temperature of this
condenser upwards.

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Split

Excluded Splits

A/B
A/BC
B/C
AB/C
A/BCD
B/CD
AB/CD
A/BCDE
B/CDE
AB/CDE

C/D

BC/D

ABC/D

C/DE

BC/DE

ABC/DE

D/E

CD/E

BCD/E

ABCD/E

A/B
A/B
A/BC, B/C
A/B, A/BC, AB/C
A/B, A/BC, AB/C, B/C
A/BC, AB/C, B/C, A/BCD,
B/CD
A/B, A/BC, A/BCD, AB/CD
A/B, A/BC, AB/C, B/C,
B/CD, AB/CD
A/BC, AB/C, B/C, A/BCD,
B/CD, AB/CD, A/BCDE,
B/CDE
A/BC, AB/C, B/C

Valid Combinations

A/BC
A/B
B/C
A/BCD
A/B
B/C, B/CD
A/BCDE
A/B

A/B, A/BCD, B/CD,

AB/CD, A/BCDE,
B/CDE, AB/CDE
A/BCD, A/BCDE, B/C

A/B, A/BC, AB/C, B/CD,

AB/CD, B/CDE, AB/CDE,
C/D
A/BCD, B/CD, AB/CD,
A/B, A/BC, AB/C,B/C
A/BCDE, B/CDE, AB/CDE,
C/D, BC/D
AB/C, A/BCD, B/CD,
A/B, A/BC,
AB/CD, C/D, BC/D, ABC/D AB/C,A/BCDE,B/CDE,AB/
CDE
A/B, A/BC, AB/C, A/BCD,
B/C, A/BCDE
B/CD, AB/CD, B/CDE,
AB/CDE, C/D, BC/D,
ABC/D, C/DE
A/BCD, B/CD, AB/CD,
A/B, A/BC, AB/C, B/C
A/BCDE, B/CDE, AB/CDE,
C/D, BC/D, ABC/D, C/DE,
BC/DE
A/BCD, B/CD, AB/CD,
A/B, A/BC, B/C,AB/C,
C/D, BC/D, ABC/D
A/BCDE, B/CDE, AB/CDE,
C/DE, BC/DE, ABC/DE
A/BCD, B/CD, AB/CD,
A/B, A/BC, B/C, AB/C,
C/D, BC/D, ABC/D, C/DE, A/BCDE, B/CDE, AB/CDE
BC/DE
A/B, A/BC, AB/C, A/BCD,
B/C, B/CD, A/BCDE, C/D,
AB/CD, B/CDE, AB/CDE,
BC/D
ABC/D, C/DE, BC/DE,
ABC/DE, D/E,CD/E
A/BCDE, B/CDE, AB/CDE, A/B, A/BC, B/C, AB/C,
C/DE, BC/DE, ABC/DE,
A/BCD, B/CD, AB/CD,
D/E, CD/E, BCD/E
C/D, BC/D, ABC/D

Table 4. Valid Component Combinations

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Split

T Bub

Load

C.Load

AB/CDE
B/CDE
A/BCDE

87.2
87.2
79.4

30.6
30.5
7.6

AB/CD
B/CD

75.5
75.5

27.2
27.2

33.8 a/b
30.5
34.8
b/cd
31.9 b/c
30.5 a/b
33.5
a/bcd

A/BCD

67.9

6.3

AB/C
B/C

62.7
62.7

A/BC

Load
63.4

T dew
97.6

Split
D/E

63.5

63.5

81.2

CD/E

62.9

62.9

75.1

BCD/E

62.3
75.5
cd/e
80.9 d/e

62.3
12.6

72.3
62.7

ABCD/E
C/D

17.5

62.7

C/DE

30.6 b/c

24.3
24.3

57.5

C.Load
63.4

27.5 a/b
29.6
a/bc

5.3

5.3

Table 5. Cumulative Heat Load Table

Component

Mole Fraction

Molal Flow kmol/hr

A: Propane

0.05

45.36

B: iso-Butane

0.15

136.08

C: Butane

0.25

226.80

D: iso-Pentane

0.20

181.46

E: Pentane

0.35

317.52

Total

1.00

907.20

Table 6. Heavens Problem

Examination of the reboilers positioned above this point indicate that changes of the
D/E condenser temperature relative to any of the following would be advantageous:
ABC/DE, BC/DE, C/DE (with the C/DE option showing the largest savings).
Examination of the Heat Load Table indicate that modifications relative to the CD/E
and BCD/E condensers have no advantage over the D/E condenser and larger
pressure changes would be required in order to bring these units into contention.
These changes need not be considered.

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Movement of the C/DE condenser relative to the D/E reboiler would be necessary to
improve savings above the isobaric systems. These savings would not exceed those
achieved by manipulating the D/E condenser position. Very much higher pressure
changes would be required. This change does not need to be considered.
Similar analysis can be applied to other condensers in the table with similar results.
Analysis of pressure manipulation is only justified for the following separations:
D/E with respect to ABC/DE
D/E with respect to BC/DE
D/E with respect to C/DE.
Integrating via feed vaporisers, intermediate condensers and reboilers
These options should only be evaluated after integration via overhead condensers
linked to base reboilers has been examined.
Advantages to be gained from cooling of column feed are generally secondary to
those to be gained through integrating phase changes. So, identification of these
should be undertaken once the scheme has been identified.
In process synthesis we should always seek to reduce the size of a problem before
going into the detail of a problem. So, is there anything we can do before we start to
examine the thermodynamic profiles of individual separations?
Well, there is no point in using an intermediate condenser below the feed plate (i.e. at
a higher temperature than the column feed) or an intermediate reboiler above the
feed plate. So, we could start by comparing overhead condenser with feed
temperatures.
This is done in Tables 7.
Examination of this table shows the opportunities that could be opened up by feed
vaporisation and the use of intermediate reboilers. Using the table we can identify
which thermodynamic profiles are worth examining.
We see that the new opportunities are:
* use of D/E condenser on the C/DE separation
* use of D/E condenser to vaporise the ABCDE feed
* use of D/E condenser to vaporise the BCDE feed
The engineer is therefore directed to examine the thermodynamic implications of
using feed vaporisation on these streams. The thermodynamics of the following
separations can then be examined:

A/BCDE
AB/CDE
ABC/DE
B/CDE
BC/DE

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FEATURE March 02

This examination will show the scope for the use of both feed vaporisation and the
use of intermediate reboilers.
Possibilities of using intermediate condensers can be determined in a similar
manner. For instance, we see from Table 7 that heat from a D/E separation can be
provided over the range 97.6 (condenser temperature) to 103 (feed temperature). So,
by examining a table which compares feed and reboiler temperatures we can identify
which separations should be subjected to thermodynamic analysis.

Feed Stream

T feed

DE

103

CDE
ABCDE
BCDE
CD

87.2
80
79.4
75.5

BCD

67.9

ABCD

60.9

BC

57.5

ABC

50.1

AB

37.5

Condenser

T dew

D/E

97.6

CD/E

75.5

BCD/E
C/DE
C/D

67.9
62.7
62.7

ABCD/E
BC/DE
BC/D
ABC/D
ABC/DE
B/CDE
B/CD
B/C

60.9
57.5
57.5
50.1
50.1
49.9
49.9
49.9

Table 7. Comparison of feed and condenser temperatures

References
Rajah W. & Polley G.T. Synthesis of Practical Distillation Schemes,
Trans.I.Chem.E. 1995, 73A,953-966
Heaven D.L. M.S. Thesis, University of California, Berkeley
Andrecovich M.J. & Westerberg A.W. A simple synthesis method based on utility
bounding for heat integrated distillation sequences, AIChEJ, 1985,31(3), 363-375

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