fi Advances in Distillation Retro t Nguyen Van Duc Long · Moonyong Lee Advances in Distillation fi Retro t NguyenVanDucLong MoonyongLee SchoolofChemicalEngineering SchoolofChemicalEngineering YeungnamUniversity YeungnamUniversity Gyeongsan Gyeongsan SouthKorea SouthKorea ISBN 978-981-10-5899-8 ISBN 978-981-10-5901-8 (eBook) DOI10.1007/978-981-10-5901-8 LibraryofCongressControlNumber:2017954336 ©SpringerNatureSingaporePteLtd.2017 Thisworkissubjecttocopyright.AllrightsarereservedbythePublisher,whetherthewholeorpartof thematerialisconcerned,specificallytherightsoftranslation,reprinting,reuseofillustrations,recita- tion,broadcasting,reproductiononmicrofilmsorinanyotherphysicalway,andtransmissionorinfor- mation storage and retrieval, electronic adaptation, computer software, or by similar or dissimilar methodologynowknownorhereafterdeveloped. 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The registered company address is: 152 Beach Road, #21-01/04 Gateway East, Singapore 189721, Singapore Preface As a thermal separation method, distillation is considered the most important and mature separation technology in the chemical process industry. While this unit operation has many advantages, one major drawback is its large energy require- ment, which significantly influence the overall plant profitability. Therefore, the increasing cost of energy has forced industry to reduce its energy consumption. In addition, many processes are required to increase capacity due to an increase of demand. To accomplish these tasks, retrofit of distillation processes become an important issue. To carry out effectively retrofit, an innovation solution is the use of advanced process integration and process intensification techniques, which has been a rapid growth in technological and commercial opportunities. In particular, multi-effect distillation, heat pump assisted distillation are the best examples of proven process integration technology, whereas thermally coupled distillation sequence (TCDS), dividing wall column (DWC), and reactive distillation are the best examples of proven process intensification technology in distillation because they have significantly lower investment and operating costs while also reducing theequipmentandcarbonfootprint. How can one decide quickly what techniques and whether they are good pro- cess concepts for distillation retrofit? This field requires a book that will capture anaccurate snapshotregarding thefieldandprovideaninsightful review toallthe key techniques in the revolution in distillation retrofit. Considering that there are alreadybooksdealingwithknownandbasicissueindistillation,thisbookaimsto provide the readers with some issues related to retrofit of distillation using advanced distillation techniques, emphasizing the use of multi-effect distillation, heat pump assisted distillation, TCDS, DWC, reactive distillation, and innovative hybrid systems, which have not been comprehensively discussed in the published books. Rather than prepare a textbook on advanced distillation in the usual and traditional format, the authors consideredwriting a book that highlighted concepts andpracticalapplicationsratherthantheory. This book presents a comprehensive review of contemporary advanced techni- ques employed for enhancing the distillation process with the purpose is bridge the gap between developers of advanced distillation design procedures and those v vi Preface ultimately use them. Thus this book is a source of information for undergraduate and postgraduate students of chemical engineering, practicing process designers andchemicalengineers. Several companies supported our work. In particular we would like to thank Samsung BP Chemicals, Samsung Cheil Industries, SKC, LG Chemical, and KOGAS. NguyenVanDucLong MoonyongLee List of Abbreviations and Greek Letters Abbreviations A Area[ft2] ABDWC Azeotropicbottomdividingwallcolumn BDWC Bottomdividingwallcolumn BC Barecost[$] BMC Updatedbaremodulecost[$] C Ethane 2 C Propane 3 C5+ Gasoline CD Coordinatedecentmethodology CE Cellulosicethanol CO Carbondioxide 2 COP Coefficientofperformance C Costofthesteam[$] steam C Costofcoolingwater[$] CW C Costofelectricity[$] electricity C Costofrefrigeration[$] refrigeration CGCC Columngrandcompositecurve D Diameter[ft] DWC Dividingwallcolumn DWPC Dividingwallprefractionatorconfiguration E Overallefficiency[%] o E Murphreestageefficiency[%] MV ECMD EnhancedCapacityMultipleDowncomer ETDWC Extractivetopdividingwallcolumn EPC Engineering,procurementandconstruction F Feedflow[kg/hr] FEED Front-endengineeringdesign vii viii ListofAbbreviationsandGreekLetters FL Liquidflow[kg/hr] FV Vaporflow[kg/hr] FTCDC Fullythermallycoupleddistillationcolumn h Enthalpy[kJ/kg] HP Highpressure iC Isobutane 4 K Distributioncoefficient L Length[ft] LLE Liquid-liquidequilibrium LP Lowpressure MD MultipleDowncomer MF Modulefactor MPF Materialandpressurefactor MVR Mechanicalvaporrecompression N Numberoftrays nBuOH Normalbutylalcohol NGL Naturalgasliquid nC Normalbutane 4 NRTL Nonrandomtwo-liquid Op Operatingcost[$] P Totalvaporpressureofthesolution p Partialpressureofcomponentiinthevapor i p′ Vaporpressureofpurecomponenti i PSA Pressureswingadsorption PFMD ParallelFlowMultipleDowncomer q Feedthermalcondition R Refluxratio RDWC Reactivedividingwallcolumn RSM Responsesurfacemethodology R2 Coefficientofdetermination S Areaoftheheatexchanger[ft2] SSC Sidestreamcolumn T Temperature[oC] TSA Temperatureswingadsorption TAC Totalannualcost[$] TCDS Thermallycoupleddistillationsequence TCEDS-SR Thermallycoupledextractivedistillationsequences TCRDS Thermallycoupledreactivedistillationsequence TDWC Topdividingwallcolumn VC Vaporcompression VLE Vapor-liquidequilibrium x Compositionofcomponentiintheliquidphase i y Compositionofcomponentiinthevaporphase i ListofAbbreviationsandGreekLetters ix UF Updatefactor UNIQUAC Universalquasi-chemical ΔT Temperaturedifference Greek letters γ Liquidactivitycoefficient µ Chemicalpotentialofcomponenti i α Relativevolatility λ Latentheat[kJ/kg] Contents 1 Introduction............................................ 1 1.1 Introduction ........................................ 1 1.2 DistillationFundamentalsandPrinciples................... 1 1.2.1 VaporPressure ................................ 2 1.2.2 Vapor-LiquidEquilibrium ........................ 4 1.2.3 DewPointandBubblePoint ...................... 5 1.2.4 EquilibriumFlashCalculations .................... 6 1.3 DistillationDesign ................................... 7 1.3.1 ShortcutMethods............................... 7 1.3.2 RigorousMethods.............................. 8 1.4 DistillationSimulation ................................ 8 1.4.1 AzeotropeSearch............................... 8 1.4.2 PhysicalPropertyMethods........................ 9 1.4.3 BinaryParameters .............................. 10 1.5 DistillationProcessRetrofit/RevampandDebottlenecking...... 10 1.5.1 ProcessIntegration.............................. 12 1.5.2 ProcessIntensification........................... 13 1.5.3 CombinationofHeatIntegrationandProcess Intensification ................................. 14 1.6 ConcludingRemarks ................................. 15 References ............................................. 15 2 RetrofitandDebottleneckingbyModifyingColumnInternal ..... 17 2.1 Introduction ........................................ 17 2.2 TypesofColumnInternal.............................. 18 2.2.1 Trays........................................ 18 2.2.2 Packings ..................................... 19 2.2.3 ColumnInternalPerformances..................... 20 2.2.4 CriteriaforSelectionofVapor-LiquidContactors....... 23 2.3 RetrofitandDebottleneckingbyModifyingColumnInternal.... 24 2.3.1 UsingHighCapacity/EfficiencyTrays............... 24 xi