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Preliminary evaluations using a simple but reliable short-cut method indicated that a 15 component aromatics
mixture can be separated very efciently into four fractions according to the given product specications employing
either a single or a multiple partition wall dividing wall column (DWC). The obtained results have been used to initiate
rigorous simulations, to determine the number of stages required in different sections, as well as to obtain internal
ows of vapour and liquid necessary for dimensioning and adequate cost estimation for two design alternatives.
Based on the comparison of total annualised costs it appears that a multi-partition wall conguration that maximizes
energy efciency is a more attractive option for implementation in aromatics processing plants than more practical
single partition wall conguration.
2011 The Institution of Chemical Engineers. Published by Elsevier B.V. All rights reserved.
Corresponding author. Tel.: +31 15 278 66 74.
E-mail address: z.olujic@tudelft.nl (Z. Olujic).
Received 1 November 2010; Received in revised form 12 January 2011; Accepted 22 January 2011
0263-8762/$ see front matter 2011 The Institution of Chemical Engineers. Published by Elsevier B.V. All rights reserved.
doi:10.1016/j.cherd.2011.01.016
1156 chemical engineering research and design 8 9 ( 2 0 1 1 ) 11551167
has to be ensured during the design phase by arranging the 3. 4-p DWC modelling and evaluation
pressure drop of each partitioned section accordingly.
In this paper, we show a comparison of a properly 3.1. Alternative 4-p DWC congurations
dimensioned single-partition wall column for obtaining four
products with a three-partition wall column. As indicated in Two feasible options for a 4-product dividing wall column (4-p
conceptual design stage and conrmed by rigorous simula- DWC) are shown schematically in Fig. 2a and b. Fig. 2a shows a
tions in present work, the latter maximizes the energy saving so-called Kaibel conguration (Kaibel, 1987; Olujic et al., 2009)
gain with respect to conventional three columns sequence. employing one partition wall, and Fig. 2b shows a so called
However such a complex internal DWC conguration has not fully extended Petlyuk conguration, that employs multiple
been attempted yet in industrial practice. As it will be demon- partitions walls. The former implies having two and the latter
strated later on, in present case a multiple-partition-wall DWC one three sections in parallel. According to various simula-
appears to be an industrially viable option. tions studies (see Dejanovic et al., 2010a), the former enables
Fig. 2 Schematic illustration of two alternative four-product DWCs: Kaibel column (2-4) and the fully extended Petlyuk
(2-3-4) congurations.
a signicant energy saving with respect to conventional con- seems to be the main reason that multiple partition wall con-
guration, which however is well below that achievable with gurations, which maximize energy saving, have not yet been
a fully extended counterpart. attempted in industrial practice.
However, the only known application so far of a 4-p DWC An objective of this paper is to demonstrate that design
is the simpler, Kaibel type column, with one partition wall, of internal conguration of a complex DWC is something that
with longitudinal sections in off-centre position (see Olujic can be done with certainty, and that column dimensioning can
et al., 2009), which was adopted because of practical reasons, be performed with some condence for applications utilising
i.e. its simpler design, construction and operation. The com- columns equipped with structured packings, using the pub-
plexity, i.e. design, operation and control related uncertainties lic domain knowledge. Namely, well established and highly
practical non-welded partition wall technology, described in According to a most recent state of the art review (Dejanovic
greater detail elsewhere (Kaibel et al., 2007; Olujic et al., 2009; et al., 2010a), the so called V-min diagram method, introduced
Dejanovic et al., 2010a), allows assembling multiple partition and elaborated in detail in recent publications by Halvorsen
wall congurations without additional difculties. and Skogestad (2003a,b,c) represents a universal engineering
Recoveries VT /F D/F N Nf
Recoveries VT /F D/F N Nf
336.2 439.1
RL=0.347
219.6 178.4
116.6 260.7
41.2 S1
343.0 178.4 178.4
281.3 85.7 S2
480.2
92.7 178.4
RV =0.624
572.8
Liquid 459.7
Vapour
V/B = 4.061 113.2 B
Fig. 6 Mass balance for 2-4 conguration, with all internal vapour and liquid ows and splits according to V-min
diagram.
tool that enables thorough and accurate assessment of poten- nent is represented by a letter according to alphabetic order.
tial for minimization of energy requirement of fully thermally Distillate and bottoms stream are represented by common
coupled distillation columns. This rather simple method is symbols D and B, while S1 and S2 denote molar ow rates of
based on assumptions of constant molar ows, innite num- lighter and heavier side product, respectively.
ber of stages, and constant relative volatilities, and therefore The basic entity of the V-min diagram is a simple two-
holds for (near) ideal zeotropic mixtures. It relies on Under- product distillation column at constant pressure with a given
woods equations utilised to estimate the value of theoretical multicomponent feed (F), which at steady state implies two
minimum boil-up ratio, outgoing from the thermodynamic degrees of freedom in operation. There are several possibili-
condition (q) and composition (z) of the feed and the K-values ties in this respect, however using the ratio of molar ow rates
or equilibrium constants of each component for given operat- of internal vapour and the feed (V/F) and the ratio of molar
ing conditions. ow rates of distillate product and the feed (D/F) appeared to
The real power of the V-min diagram is that it contains be most appropriate choice. Namely, for each given pair (D/F,
all necessary information to calculate the overall minimum V/F) all other properties are completely determined, such as
energy requirement and all the internal ow rates for an opti- all component recoveries and product compositions.
mally operated extended Petlyuk arrangement for an arbitrary
multicomponent feed and any number of products (Halvorsen D
and Skogestad, 2003c). Here, Halvorsen and Skogestad have
also shown that an optimally operated generalized Petlyuk
arrangement results in the lowest overall vapour ow require-
ment for any distillation conguration when we consider C3.1
constant pressure and no external heat integration.
We would generally anticipate that we would need to cal-
culate the minimum energy for each succeeding column by C2.1 S1
a new column computation, but Halvorsen and Skogestad
(2003b) showed that the properties determining minimum
F
energy in each sub-column can be found from the previous C1
column. This practically means that regardless the complex- C 3.2
ity of a situation, the V-min diagram containing all necessary
S2
information can be constructed based on feed data only.
Importantly, this simple method that in original graphical C2.2
form provides direct insight into the optimal separations
behaviour in fully thermally coupled column arrangements
can be easily translated into analytical form and implemented
C3.3
into a commercial process simulator, as it was done in present
paper to generate reliable initial guesses for rigorous simula-
tions. B
The composition of the feed considered in this study is
given in Table 2, with component K-values corresponding to Fig. 7 Partitioned part of a DWC according to 2-3-4
feed stage conditions, and component grouping according to conguration, with three sections of main column
actual product specications. For convenience, each compo- superimposed on that representing 2-4 conguration.
1160 chemical engineering research and design 8 9 ( 2 0 1 1 ) 11551167
Fig. 9 Mass balance of 2-3-4 conguration with all internal vapour and liquid ows according to V-min diagram.
chemical engineering research and design 8 9 ( 2 0 1 1 ) 11551167 1161
light and heavy keys for that column while the intermediates
distribute to both ends.
The split between toluene (H) and ethylbenzene (I), repre-
sented by the highest peak in V-min diagram shown in Fig. 8,
requires the largest vapour ow rate, which means that this
amount of vapour is generated by the reboiler and will be used
for all separations involved. Internal mass balances are then
used to determine each individual vapour and liquid load.
For instance, the interaction between two sections of the cen-
tral column and the middle section of the main column, i.e.
C2.1 C3.2 C2.2 , is described by following balance expressions
where the negative sign indicates stream going towards cen-
tral column, and positive sign the stream going towards main
column.
C3.2
FV = VTC2.2 VBC2.1 (1)
FLC3.2 = LC
B
2.1 LC2.2
T (2)
Q C=-5055 kW
w(benzene)=1.3%
656.5 557.4
2,1 N=20
651.9 552.9
86.5
287.1 203.0
w(toluene)=98.1%
311.5 508.4 2,4a N=22
1,2a N=10 287.2 203.1
345.1 542.1
287.2 203.1
345.7 542.7 2,4b N=22
1,2b N=11 277.1 193.0
346.4 546.0
633.9 746.7
2,5a N=15
618.3 734.9
615.0 731.1
2,5b N=15
604.1 716.9
w(toluene)=0.06%
QR =5821 kW
Fig. 12 Mass balance of 2-4 conguration with all internal vapour and liquid ows according to rigorous model.
It should be noted that use of commercial process sim- 3.3. Detailed modelling approach
ulator for short-cut simulation of 2-4 conguration is not
so straightforward. This case cannot be modelled as a series Sequences used for simulation of proposed congurations are
of binary distillation calculations of the same feed, because shown in Fig. 3. All sections stage numbers were initially set
prefractionator column is not operated at a preferred split, at effectively innite values (>4Nmin ). Side stream ows rates
causing higher energy use in subsequent sections. A way of were initially set according to the material balance. Reux
performing simulations is to use the base case conguration ratio was adjusted to keep top and bottom products purities
in Fig. 1, but with liquid fractions of the feed into the nal at specied levels, and boil-up ratio was set to provide neces-
two columns set to the effective liquid fraction of the ther- sary vapour ow from the reboiler, as calculated from V-min
mal coupling. This will give an articial superheated feed to diagram. Initial values of vapour and liquid split ratios were
the upper column and an articial sub-cooled feed to the lower also set as calculated from V-min diagram, and then tuned in
column giving the same ow changes at the junctions as in the order to keep heavy key and light key recoveries in sections
fully thermally coupled 2-4 conguration in Fig. 3. However, top and bottom respectively, below 0.01.
this may in some cases give convergence problems because The actual number of stages was then found using fol-
the articial temperatures may become close to critical lowing procedure. Keeping boil-up ratio constant, number of
values. stages in each section was gradually reduced, to the values
Table 5 Comparison of energy requirements of studied sequences, estimated using shortcut and detailed methods.
Base case 2-4 2-3-4
Shortcut method
Vmin /F 2.21 1.34 1.11
Relative savings in reboiler duty (%) 39.4 49.8
Rigorous method
Total QR, [MW] 10.03 5.82 4.81
Total QR/F [MW/t] 0.324 0.183 0.152
Relative savings in reboiler duty (%) 42.0 52.0
chemical engineering research and design 8 9 ( 2 0 1 1 ) 11551167 1163
Column C1 C2 C3
Shell tangent to tangent height (m) 40.5 39.5 39.5 63.8 60.4
Shell diameter (m) 2.0 2.0 1.8 2.2 2.1
Top pressure (bar) 1.70 2.70 1.01 2.2 2.2
Pressure drop (bar) 0.313 0.272 0.244 0.150 0.137
Reboiler duty (MW) 3.76 3.12 3.15 5.82 4.81
Total reboiler duty (MW) 10.03 5.82 4.81
Number of stages/trays 40/61 38/59 38/59 129/ 130/
Number of packed beds 10 (7) 13 (10)
Number of distributors 10 (7) 11 (8)
Number of liquid catchers 8 (5) 9 (6)
Number of support grids 10 (7) 13 (10)
Note: Numbers in parentheses indicate devices placed in partitioned part of the column.
where product purities were still not compromised. Then, effectively means that liquid and vapour ows and prop-
reboiler specication was changed to automatically adjust to erties are known for every column stage. In conventional
keep bottom product purity. Number of stages in each section column design, the dimensioning has to ensure stable col-
was proportionally reduced, and split ratios tuned to achieve umn performance with regards to liquid and vapour loads. In
desired side product purities. DWCs, dimensioning has one additional purpose, and that is
Effectively, optimization has been performed by gradually to ensure desired vapour split below the partition wall. Unlike
minimizing (in each step) the product of the number of stages liquid split, which can be set precisely by an external device,
and the reux ratio: N(R + 1), which represents a good approx- vapour split ratio is self-adjusting and is set by the govern-
imation of total annualized costs. ing pressure drops across different column sections. In other
Detailed calculation is effectively done following these words, in order to be able to precisely tune the vapour split, the
steps: designer needs to be able to accurately predict and manipulate
accordingly the pressure drop of column sections separated by
1. Chose appropriate conventional column sequence. the partition wall. In conjunction with the xed liquid split, the
2. Use values from V-min diagram, including stage number, pressure drop depends on the type and size of internals used.
for initialization. If a bed, sized to ensure given separation, does not generate
3. Keeping product purities at specied levels, using split sufcient pressure drop to ensure required vapour split, addi-
ratios to minimize reboiler duty. tional pressure drop can be arranged for instance by adjusting
4. Gradually reduce number of stages, repeating step 3, until the free area of liquid distributors and/or catchers accord-
min(N(R + 1)) is achieved. ingly.
The 2-4 conguration appeared to be rather simple in
3.4. Dimensioning this respect. Additional challenges are associated with present
attempt to evaluate feasibility of a multiple-partition wall
Dividing wall columns can be equipped with trays, random column, which means going beyond the limits of practical
or structured packing, same as conventional columns, but experience of J. Montz GmbH, the pioneer in this eld among
peculiarities, i.e. essential details associated with hydraulics equipment manufacturers, which was involved with design
and consequently dimensioning of these columns are not and delivery of more than 90 packed DWCs so far.
described in open literature. Fig. 10 shows schematically ow resistances as encoun-
The basis for dimensioning is a converged column pro- tered in the partitioned part of a 2-3-4 conguration DWC. In
le obtained by rigorous column steady-state simulation. This
Table 7 Equipment and utilities cost, and total annualised cost (TAC) for 2-4 and 2-3-4 congurations.
Conguration Conventional 2-4 2-3-4
Equipped with Sieve trays Structured packings Structured packings
Q C =-4038 kW
w(benzene)=1.3%
514.4 414.9
3,1 N=18
516.4 416.8
44.6
343.0
86.5
494.0 606.4
3,6a N=21
493.6 605.1
492.7 603.9
3,6b N=21
472.3 584.7
w(toluene)=0.06%
Q R =4806 kW
Fig. 13 Mass balance of 2-3-4 conguration with all internal vapour and liquid ows according to rigorous model.
order to arrive at required vapour splits, following conditions for with respect to standard version of the same specic
must be satised: geometric area. MN series combines a shorter smooth bend
with a decreased corrugation inclination angle, generat-
pRF + pRG = pRA (3) ing additional pressure drop due to increased interaction
of crossing vapour streams, which however translates into
pRH + pRI = pRB (4) more efciency, while preserving a rather high capacity.
More detailed information on the performance characteristics
pRX = pRG + pRH (5) of this new generation, high performance Montz struc-
tured packings can be found elsewhere, e.g. Olujic et al.
In present case, with pronounced differences in the num- (2010).
ber of stages and ow rates of phases in parallel sections The dimensioning procedure for a packed DWC can be
of the column, different types and sizes of J. Montz cor- described as following:
rugated metal sheet structured packings of series B1 have
been considered to provide enough exibility in this respect. 1. Choose packing type.
Two basic structured packing area sizes were considered as 2. Calculate required packing height in each section via HETP.
appropriate for this case, 250 and 350 m2 /m3 , respectively, in 3. Find critical vapour load and use it to determine overall
conjunction with different corrugation inclination angles as column diameter.
well as designs, i.e. M and MN. For the same specic geo- 4. Adjust wall positions, until calculated pressure drop in
metric area, using a packing with 60 instead of common all sections is below 3 mbar/m. If that is not achievable,
45 means a nearly factor three drop in the pressure drop, increase overall column diameter.
and a 30% higher capacity, at the expense of some 20% loss 5. Choose internals, using liquid loads for guidelines. Use
of efciency (Olujic et al., 2002). Packings of series M have chimney tray for side-stream draw-offs, regardless of liquid
a long smooth bend at the end of the corrugations, which load.
reduces the pressure drop and increases the capacity accord- 6. Adjust free areas of collectors in divided section, to achieve
ingly. equal calculated pressure drops, ensuring required vapour
If this packing is used at vapour loads below the loading splits. If that is not achievable, adjust wall position, and
point then some 10% loss of efciency should be accounted repeat calculations.
chemical engineering research and design 8 9 ( 2 0 1 1 ) 11551167 1165
5. Conclusions
Regarding the scale of this and similar applications, addi- Douglas, J.M., 1988. Conceptual Design of Chemical Processes.
tional 17.7% saving in operating costs translates into large McGraw-Hill.
nancial benets. Therefore in present and similar cases there Halvorsen, I.J., Skogestad, S., 2003a. Minimum energy
consumption in multicomponent distillation. 1. Vmin diagram
may be a strong incentive to put more effort and resources into
for a two-product column. Ind. Eng. Chem. Res. 42, 596604.
overcoming potential barriers and making multiple-partition Halvorsen, I.J., Skogestad, S., 2003b. Minimum energy
wall DWC congurations industrially viable. consumption in multicomponent distillation. 2.
Thanks to the availability of proven non-welded, self-xing Three-product Petlyuk arrangements. Ind. Eng. Chem. Res. 42,
partition wall structured packing technology, multiple par- 605615.
tition wall congurations could be realized in practice. If it Halvorsen, I.J., Skogestad, S., 2003c. Minimum energy
appears that control of the complex DWCs (subject of an consumption in multicomponent distillation. 3. More than
three products and generalized Petlyuk arrangements. Ind.
ongoing research effort at NTNU) will not be too demanding
Eng. Chem. Res. 42, 616629.
(impractical), than the barriers other than technical need to Halvorsen, I.J., Skogestad, S., 2006. Minimum energy for the
be overcome to enable practical implementation of this highly four-product Kaibel-column. In: AIChE Annual Meeting , San
sustainable distillation column technology. Francisco (paper 216d), November 1217, 2006.
Humphrey, J.L., Keller II, G.E., 1997. Separation Process
Acknowledgement Technology. McGraw-Hill, New York.
Kaibel, G., 1987. Distillation columns with vertical partitions.
Chem. Eng. Technol. 10, 9298.
The authors would like to thank INA Renery Sisak, Croatia, Kaibel, B., Jansen, H., Rietfort, T., Zich, E., Olujic, Z., 2007. Unxed
member of MOL Group for providing actual plant data for the wall: the key to a breakthrough in dividing wall column
purposes of this study. technology. In: Proceedings of Distillation Topical Conference,
AIChE Spring National Meeting , Houston, Texas, USA, 2227
April, pp. 2941.
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