Energy efficient control of a BTX dividing-wall column

Dividing-wall column (DWC) is considered nowadays the new champion in distillation, as it can bring substantial reduction in the capital invested as well as savings in the operating costs. This work presents the simulation results of energy efficient control and dynamics of a dividing-wall column (DWC). In order to allow a fair comparison of the results with previously published references, the case-study considered here is the industrially relevant ternary separation of the mixture benzene-toluene-xylene (BTX) in a DWC. Rigorous simulations were carried out in Aspen Plus and Aspen Dynamics. Several conventional control structures based on PID control loops (DB/LSV, DV/LSB, LB/DSV, LV/DSB) were used as a control basis. These control structures were enhanced by adding an extra loop controlling the heavy component composition in the top of the prefractionator, by using the liquid split as an additional manipulated variable, thus implicitly achieving minimization of energy requirements. The results of the dynamic simulations show relatively short settling times and low overshooting especially for the DB/LSV and LB/DSV control structures. Moreover, the energy efficient control proposed in this work allows the operation of DWC with minimum energy requirements or maximum purity of products.     

Optimal operation of Petlyuk distillation: steady-state behavior

The “Petlyuk” or “dividing-wall” or “fully thermally coupled” distillation column is an interesting alternative to the conventional cascaded binary columns for separation of multi-component mixtures. However, the industrial use has been limited, and difficulties in operation have been reported as one reason. With three product compositions controlled, the system has two degrees of freedom left for on-line optimization. We show that the steady-state optimal solution surface is quite narrow, and depends strongly on disturbances and design parameters. Thus it seems difficult to achieve the potential energy savings compared to conventional approaches without a good control strategy. We discuss candidate variables which may be used as feedback variables in order to keep the column operation close to optimal in a “self-optimizing” control scheme.     

Control and optimization of the divided wall column

The divided wall column (DWC) is, in terms of capital costs and energy savings, a promising alternative for separating ternary mixtures. Since its design was proposed, almost 50 years ago, many authors have addressed design considerations. Operation and control of the DWC have received much less attention. However, some works have been published recently. Preliminary results reported indicate that feedback diagonal control structures may be used to control the DWC. In this work, the study of feedback diagonal control strategies has been further extended to consider the DWC control design in detail. Different control structures have been systematically analyzed and compared under performance and robustness considerations. In order to study the effect of the energy optimization on the controllability of the DWC, a column at optimal nominal operating conditions is compared to a column under non-optimal operation. Finally, a complete control strategy is proposed. Linear analysis tools are used for the multiple input multiple output (MIMO) feedback control analysis, and simulations using a non-linear model are performed to study the non-linear behavior of the control systems.     

Controllability analysis of modified Petlyuk structures

Fully thermally coupled distillation columns (Petlyuk‐type columns) represent an interesting alternative to conventional distillation sequences used in multicomponent mixture separation processes, due to potential savings in both energy and capital costs. However, possible operational difficulties have limited the industrial applications of Petlyuk systems. Some of the control challenges result from the transfer of vapour stream back and forth between columns. This means that those columns do not display a uniform lower or higher pressure with respect to the other. Recently, some alternative Petlyuk‐type schemes that might provide better operation properties than the traditional Petlyuk column have been proposed. In this work, the theoretical control properties of six alternative schemes to the Petlyuk system were obtained and compared. This was performed by using the singular value decomposition (SVD) technique in the frequency domain. Also, dynamic closed‐loop responses for set point tracking and disturbance rejection were obtained to support the theoretical control properties. The results showed that the reduction in the number of interconnections and the use of unidirectional flows affected the dynamic properties of the complex schemes leading to potential operational advantages in thermally coupled distillation sequences.     

Design of a fully thermally coupled distillation column based on dynamic simulations

A dynamic simulation of a fully thermally coupled distillation column is conducted for the design of a possible operation scheme, and its performance is examined with an example process of butanol isomer ternary system. The outcome of the dynamic simulation indicates that the column can be operated by using a 3 × 3 control structure. The structure consists of three controlled variables of the compositions of overhead, bottom and side products and three manipulated variables of the flow rates of reflux and steam and liquid split ratio between a main column and a prefractionator. This paper was presented at The 5th International Symposium on Separation Technology-Korea and Japan held at Seoul between August 19 and 21, 1999.     

Design of a fully thermally coupled distillation column for hexane process using a semi-rigorous model

An industrial scale hexane process is designed for the implementation of a fully thermally coupled distillation column (FTCDC). A semi-rigorous material balance and Peng-Robinson equilibrium relation are utilized in the structural design. The operational design is conducted with a commercial design program, the HYSYS. The design outcome of the structural design indicates it to be comparable with the practical system of a conventional two-column arrangement in field operation, which shows the effectiveness of the design procedure implemented here. The procedure is good for the system of many components found from actual field applications. In addition, an investigation of the energy requirement of the FTCDC and a conventional system shows that an energy saving of 34.1% is available with the FTCDC.     

烷烃分离热偶精馏的模拟研究

选用ASPENPLUS软件中的严格精馏模型 (Radfrac) ,模拟计算了烷烃分离的常规精馏过程 ,得到了常规精馏输入总热量为 3 .0 2× 1 0 7kJ·h- 1 ,分离过程的力学效率为 2 8.6 %。在此基础上提出了该分离物系的热偶精馏系统 ,并利用ASPENPLUS软件中的多塔精馏模型 (Multifrac)对热偶精馏的多解现象进行了模拟计算和探讨 ,再由灵敏度分析模块 (Sensitivity)确定了能耗最小、操作稳定的最佳设计条件 ,即当回流比为 5 .0时 ,取内连气相流股流量为 2 1 9.3kmol·h- 1 ,内连液相流股流量为 1 75 .6kmol·h- 1 。在以上设计条件下该热偶精馏输入总热量为 2 .0 7× 1 0 7kJ·h- 1 ,热力学效率为 37.2 %。结果表明 ,烷烃分离的热偶精馏可以节约供热量 31 .5 % ,热力学效率可以提高8.6 %。     

Thermal coupling links to liquid‐only transfer streams: An enumeration method for new FTC dividing wall columns

Novel dividing wall columns (DWCs) can be obtained by converting thermal couplings to liquid‐only transfer streams. Here, we develop a simple four‐step method to generate a complete set of DWCs containing n ? 2 dividing walls, for a given n‐component fully thermally coupled (FTC) distillation. Among the novel DWCs, some easy‐to‐operate DWCs possess the property that the vapor flow in every section of the DWC can be controlled during operation by means that are external to the column. We develop a simple method to enumerate all such easy‐to‐operate DWCs. We expect that the easy‐to‐operate DWCs can be operated close‐to‐optimality; leading to a successful industrial implementation of the n‐component (n ≥ 3) FTC distillation in the form of a DWC. As an illustration, we show figures of all easy‐to‐operate DWCs with two dividing walls for the four‐component FTC distillation. © 2015 American Institute of Chemical Engineers AIChE J, 62: 1200–1211, 2016