Improving the distillation energy

network
E
nergy costs are the largest percentage of a
hydrocarbon plants operating expenditures.
This is especially true of the distillation
process, which requires substantial energy
consumption. Concerns over recent high costs
and economic pressures continually emphasise
the need for effcient distillation design and
operation without a loss of performance.
This article illustrates how energy-effcient
design can be applied in a distillation unit
through optimisation between the distillation
column and heat network system. Through a case
study, a successful retroft of an aromatics distil-
lation unit is discussed. Detailed retroft activities,
including complex heat network evaluation,
process simulation modelling and energy-friendly,
high-performance distillation equipment imple-
mentation, are described.
Strategies for improving the distillation
energy network
As continuous distillation requires simultaneous
heat input and removal (thus requiring signif-
cant energy consumption), complex heat
integration becomes more common for modern
distillation units to improve unit energy eff-
ciency. Since a distillation columns degree of
separation and enthalpy balance infuence each
other, it is critical to evaluate and optimise the
distillation column and heat exchanger networks
together in order to maximise plant economics.
There are numerous strategies to improve the
energy effciency of distillation processes, with
the amount of improvement through each strat-
egy varied according to process conditions. The
following are common strategies that can be
Soun Ho Lee GTC Technology
Kwang Gil Min GS Caltex Corporation
applied to practical energy improvement
projects.
Feed temperature
Feed temperature is a major factor infuencing
the overall heat balance of a distillation column
system. Increments in the feed enthalpy can help
reduce the required energy input from the
reboiler at the same degree of separation.
Installing a feed preheater is a very common
process option to minimise reboiler heat duty. If
the feed preheater can be integrated with other
valuable process streams (as a heating medium),
overall energy effciency of the distillation
system can be improved further. However,
increasing the feed temperature does not always
improve the overall energy effciency of a distil-
lation unit. Excessive feed temperature
increments can cause a signifcant amount of
fash of heavy key and non-key components at
the distillation column feed zone. In this case, a
higher amount of refux stream is necessary to
maintain required overhead distillate purities.
This augmented refux ratio thus requires a
higher boil-up ratio. Overall energy effciency is
eventually aggravated.
1
Therefore, careful review
of the feed temperature and phase is critical to
minimise the overall energy consumption of the
distillation unit.
Feed location
Improper feed location of a distillation column
can also increase the refux/boil-up ratio and
energy consumption. An ideal feed location is a
section of the distillation column where the
composition of column internal liquid traffc is
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Energy-efcient design applied to the ret of a distillation unit was achieved
through optimisation between the distillation column and heat network system
similar to feed stream composition. In this case,
the composition gradient between feed stream
and distillation internal fuids is minimised. In
actual operation of the distillation column, feed
compositions are often changed from the origi-
nal design conditions. In cases of signifcant
deviation, discrepancy between column internal
liquid composition and feed stream composition
can increase, which results in a non-optimum
feed location. Therefore, evaluating feed location
is an essential step for successful distillation unit
energy improvement.

Inter-condensers and inter-reboilers
Adding inter-condensers and/or inter-reboilers
can help improve overall energy effciency.
Pumparound, one of the inter-condenser
concepts, has been widely applied to numerous
petroleum multi-product fractionators. On the
other hand, implementing an intermediate
reboiler can reduce the main reboiler duty. As
the required temperature of an intermediate
reboiler is lower than that of the main reboiler,
this strategy may allow heat integration with
other valuable heat sources that are not as costly
or not fully utilised in the plant.
Column operating pressure
Relaxation of the column top operating pressure
decreases the distillation columns temperature
profle and results in a lower reboiler duty. It
has been observed that numerous commercial
distillation columns have been operated with
lower operating pressures than their original
design values. However, this strategy is not
2 Revamps 2013 www.digitalrening.com/article/10008553
applicable to columns operated under
an atmospheric pressure range.
Column overhead circuit pressure drop
and condenser temperature approaches
both heavily infuence feasibility. In
addition, column pressure reduction
expands vapour traffc and pushes the
limits of existing distillation
equipment.
Column pressure drop
Reducing column pressure drop can
lower reboiler duty at the same degree
of separation. The amount of reboiler
duty saving relies on operating pres-
sure and enthalpy balance. This
strategy is generally feasible when the
distillation column is operated under vacuum
pressure range. Meanwhile, pressure drop
improvement does not often provide noticeable
energy savings in high-pressure range distilla-
tion service.
Column efciency improvement
Column effciency improvement can reduce the
refux/boil-up ratio at a given degree of separa-
tion. This strategy can be delivered by
increasing the number of theoretical stages
and/or enhancing the effciency of distillation
equipment. The feasibility can be gauged by a
dedicated sensitivity analysis. Constructing a
column effciency curve with a refux ratio is
one of the core tools for sensitivity analysis. A
typical curve is shown in Figure 1. This curve
visualises column effciency sensitivity and
energy-saving gain. The curve can be catego-
rised by three district zones: steep, moderate
and fat sensitivity.
2

Column effciency improvement is usually very
feasible when the refux ratio falls into the steep
sensitivity zone and at ratios considerably in
excess of the minimum refux ratio. In this
scenario, even the small addition of stages, or an
increase in distillation equipment effciency, can
enhance overall column separation with signif-
cant energy reductions.
Improvement gain is diluted in the moderate
sensitivity zone. Further detailed feasibility study
is necessary through economic analysis. The
magnitude of energy savings is negligible when
refux ratio variation follows fat motion in the
remaining zone.
Steep
sensitivity zone
Moderate
sensitivity zone
Flat sensitivity
zone
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Figure 1 Typical column efciency vs reux ratio curve
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Case study: unit description
The following is a revamp
case study of a xylene
mixture separation unit that
demonstrates well-thought-
out, proven design practices
and a selection of the
correct, high-effciency
distillation equipment to
fulfll the improvement in
energy effciency. Figure 2
illustrates the xylene mixture
separation units confgura-
tions under discussion. This
schematic reveals that the
original distillation units
have implemented the full
heat integration network for
energy-effcient operation.
The function of the xylene
column is to separate the
feed mixture to xylene
components and heavier C
9
+
components. This column
has two different feed
sources. The reformate split-
ter bottom stream and the
toluene column bottom stream (which belongs
to the aromatic extraction unit) are introduced
as the xylene column bottom feed stream. The
bottom feed stream is split equally and charged
to two different feed trays. The reformate split-
ters bottom stream is treated at the clay towers
to eliminate traced olefn components before
charging to the xylene column. Meanwhile, the
deheptaniser bottom stream (from the xylene
isomerisation unit) is charged as the xylene
column top feedstock. This stream is also split
and introduced to three different feed trays.
The xylene column overhead vapour stream is
split into three parallel streams. Two vapour
streams are utilised as the heat source of the
extract column reboiler and the raffnate column
reboiler, respectively. The condensed xylene
column overhead liquid streams are returned to
the xylene column receiver. The other vapour
stream is supplying heat to the xylene column
overhead steam generator, which produces #250
steam. The condensed overhead liquid stream is
also returned to the xylene column receiver. The
overhead distillate of the xylene column is sent
to the paraxylene recovery unit.
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In the xylene column reboiler circuit, the xylene
column bottom reboiler inlet stream is frst trans-
ported to the other two distillation column
reboilers as heating mediums. After providing
heat to these reboilers, the xylene column bottom
streams are combined and introduced to the
furnace-type xylene column reboiler.
In the paraxylene recovery unit, the xylene
components from the xylene column are sepa-
rated through the adsorption process. The
pre-separated extract stream from the adsorp-
tion process is charged to the extract column in
order to separate paraxylene from the desorbent.
At the same time, the pre-separated raffnate
stream from the adsorption process is charged to
the raffnate column to rectify the raffnate
components (metaxylene, orthoxylene and ethyl
benzene) as a side-cut product.
3
A pasteurising
section is arranged at the top of the raffnate
column to remove moisture from the side-cut
product.
4
Case study: process evaluation for energy
efciency improvement
To achieve an additional gain in energy eff-
Mixed
xylene
Top
feed
Bottom
feed
Xylene
column
Extract
column
Raffinate
column
Steam
generator
C
9
+
Figure 2 Xylene column heat network conguration
ciency, a dedicated process evaluation was
conducted for the unit. Column operating condi-
tions were frst compared to the original design
conditions. This comparison helps comprehend
deviations between the original design and the
actual operational environment. It was observed
that the actual product purities of the xylene
column were higher than the aromatic rundown
product requirements. Relaxing the degree of
separation of the xylene column can reduce the
refux and boil-up ratio, as well as save fuel
consumption for the xylene column furnace
reboiler. However, the xylene column overhead
vapour streams are utilised as the raffnate and
extract column reboiler heating mediums, and
contribute steam production in the current unit
energy network. Lower refux/boil-up ratios in
the xylene column decrease the amount of
xylene overhead vapour used
as heating medium for the
extract/raffnate column and/
or steam generation.
Process simulation model-
ling was utilised as part of the
process evaluation activities to
quantify and predict gains in
energy effciency. Equilibrium
base simulation software was
utilised for the modelling.
Base simulation modelling
was frst constructed through
pertinent unit test run data.
Gathered major process
stream fow rates were veri-
fed via fow meter orifce
calculations. Regular stream
composition analysis reported
bulk compositions for non-key
components such as non-aro-
matic and C
9
+ component
groups. Preliminary simula-
tion modelling showed that
component assumptions for
these component groups
varied simulation results
signifcantly. To improve
accuracy of simulation,
detailed component analysis
was specially arranged for the
test run.
Detailed component analysis
was utilised for rigorous simu-
lation modelling. Key component balance closures
for the extract and raffnate columns were less
than 3%. Reconstructed feed compositions using
products were applied for the simulation of the
extract and raffnate columns. For the xylene
column, the given overall mass balance closure
was off by 5%. It was found that measured feed
rates were more reliable than product rates, and
bottom product rate was less reliable through
overall unit mass balance investigation. Based on
this investigation, simulation modelling for the
xylene column focused on matching feed and
overhead distillate rates.
A reasonable matching refux temperature as
well as rate is critical to quantify reliable column
internal traffc conditions. It has been observed
that matching refux temperature is often over-
looked in simulation modelling. Refux rate is
4 Revamps 2013 www.digitalrening.com/article/10008553
Table 1
Case parameter Pre-revamp test run Simulation results
Extract column
Column top temperature, F Base + 0.9F
Column bottom temperature, F Base + 1.1F
Reboiler return temperature, F Base + 0F
Reux ratio (to overhead distillate), volume Base +1.1%
Reux temperature, F Base 0
Overhead distillate rate, BPD Base 0
Bottom rate, BPD Base 0
p-DEB impurity in overhead distillate, wt ppm Base 0
Xylene impurity in bottom, wt ppm Base 0
Rafnate column
Column top temperature, F Base + 6.7F
Side cut draw temperature, F Base - 4.3F
Column bottom temperature, F Base - 0.5F
Reboiler return temperature, F Base - 2.9F
Reux ratio (to side cut), volume Base -0.58%
Reux temperature, F Base 0
Overhead distillate rate, BPD Base 0
Bottom rate, BPD Base 0
p-DEB impurity in side cut stream, wt ppm Base 0
Xylene impurity in bottom, wt ppm Base 0
Xylene column
Column top temperature, F Base - 0.9F
Column bottom temperature, F Base 0F
Reboiler return temperature, F Base - 2.25F
Reux ratio (to overhead distillate), BPD Base + 0.04%
Reux temperature, F Base 0F
Overhead distillate rate, BPD Base -0.1%
Bottom rate, BPD Base -5%
C
9
+ impurity in overhead distillate, wt ppm Base 0
Xylene impurity in bottom, wt ppm Base 0
Pre-revamp test run and base simulation: comparison of results
usually metered at a fow
meter located on the refux
piping. When the external
refux rate is recycled back to
the column, the internal refux
rate will vary, depending on
the external refux tempera-
ture. Therefore, a poor
matching refux temperature
in the simulation will not
predict the actual internal
column traffc accurately. This
can result in erroneous eff-
ciency assumptions of the
existing column or provide a
misleading, incorrect result.
Instrumentation for measur-
ing the pressure drop of the
extract and raffnate columns
was not pertinent. Matching
pressure drop was ignored in
simulation modelling; instead,
matching column temperature
data were focused on.
Temperature profles are more
important to predict distilla-
tion column energy
consumptions. Table 1
summarises the base model
simulation results and
compares test run data for the
three columns. This table
depicts that base model results
were reasonably matched to
the test run data. As
mentioned earlier, the xylene
column bottom rate was not matched. Through
various sensitivity analyses, the tray effciencies
of the columns were quantifed.
5

Extensive case studies were performed for the
feasibility of energy effciency improvement in
the unit. The case studies focused on energy
consumptions in the extract and raffnate
columns. Energy improvements in the other two
distillation column reboilers in the xylene
column reboiler circuit also help reduce fuel
consumption in the xylene column furnace
reboiler, but magnitude was not signifcant.
Since both columns are operated under atmos-
pheric pressure, reducing column operating
pressure is not applicable. In addition, feed
streams of both of the columns are preheated by
bottom product streams. Adding independent
feed preheaters was not feasible due to limited
plot and poor economics. The study showed that
reducing column pressure drop using the
low-pressure drop nature of trays does not
deliver reboiler duty savings in both of the
columns.
Case study results for column effciency
improvement showed that energy effciency
improvement was feasible. The column effciency
curves were constructed using simulated refux
ratio and theoretical stage values, and base
modelling and improved column effciency
points were plotted. Figures 3 and 4 display
these curves. An improved column effciency
point was predicted through an increased
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2.1
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Theoretical stage number
Pre-revamp test run
Revamp design
Pre-revamp degree of separation
Figure 3 Extract column sensitivity analysis (revamp design)
2.1
2.3
2.2
2.0
1.9
1.8
1.7
1.6
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Theoretical stage number
Pre-revamp test run
Revamp design
Pre-revamp degree of separation
Figure 4 Rafnate column sensitivity analysis (revamp design)
number of trays. Simulated tray effciency values
of the base model were maintained for the
improved column effciency case study. Extra
individual tray effciency improvement was not
considered. Original trays were arranged with
600 mm (~24) regular tray spacing. The
increased number of trays was predicted through
a reduced tray spacing scenario: 450 mm (~18)
regular tray spacing. As a higher tray count can
increase the column pressure drop, increased
column pressure drop values were applied for
case studies of column effciency improvement.
The charts in Figures 3 and 4 show that the
refux ratios of the columns were positioned in
the steep sensitivity zone and that enhancing
column effciencies is benefcial to improve
energy consumption in both columns. Reduced
reboiler duties of the extract and raffnate
columns contribute to the xylene column furnace
reboiler duty saving in the unit energy network.
Column modication
Based on the case study
results, the extract and raff-
nate columns were modifed.
The number of trays was
increased in both of the
columns. At a given column
shell height, a higher
number of trays requires
short tray spacing, causing
tray capacity loss. To prevent
column capacity reductions,
GT-Optim high-performance
trays were implemented and
replaced the original sieve
trays in both of the columns.
The original xylene column
trays remained unchanged.
The higher- capacity nature
of the GT-Optim tray main-
tains the desired column
capacity with shorter tray
spacing. In addition, the eff-
ciency enhancement features
of these trays can help to
maximise column effciency.
Various performance-en-
hancing features adapted in
the trays improve the
vapour-liquid contact mech-
anism and enhance tray
effciency. These include specialised, shaped
downcomers, liquid inlet momentum breakers,
tray inlet vapour/liquid contact initiation devices
and directional valves positioned in the tray
periphery area. Tray pressure drop was opti-
mised to prevent a too low tray vapour velocity
that can downgrade tray effciency due to
insuffcient vapour/liquid contact volume.
Various performance-enhancing features of
GT-Optim trays were added to improve tray eff-
ciency. Nevertheless, extra individual tray
effciency improvement was not counted for a
conservative approach to revamp design. Applied
tray effciencies for the revamp design were the
same as the sieve tray effciencies obtained
through simulation modelling of the pre-revamp
test run.
Original trays for the pasteurisation section of
the raffnate column were designed with a three-
pass geometry. A chimney tray was positioned
between three-pass pasteurisation section trays
6 Revamps 2013 www.digitalrening.com/article/10008553
Case parameter Pre-revamp test run Post-revamp test run
Extract column
Feed rate, BPD Base +18%
Overhead distillate rate, BPD Base +36%
Feed temperature, F Base + 2.3F
Reux temperature, F Base + 16.9F
Column top pressure, psi Base + 1.3 psi
Reux ratio (to overhead distillate), volume Base -28%
p-DEB impurity in overhead distillate, wt ppm Base - 1 ppm
Xylene impurity in bottom, wt ppm Base + 16 ppm
Rafnate column
Feed rate, BPD Base +14%
Side cut product rate, BPD Base +28%
Feed temperature, F Base + 5.6F
Reux temperature, F Base + 0.1F
Column top pressure, psi Base +1.4 psi
Reux ratio (to side cut), volume Base -6%
p-DEB impurity in side cut, wt ppm Base + 23 ppm
Xylene impurity in bottom, wt ppm Base + 4 ppm
Xylene column
Feed rate,
1
BPD Base +30%
Unit reboiler fuel consumption,
2
EFO BPD/BPD Base -22%
Unit reboiler fuel consumption,
3
EFO BPD/BPD Base -9%
250# steam generation, lb/hr Base +26%
Note
1. Total feed rate.
2. Equivalent furnace fuel oil consumption rate per feed charge rate.
3. Simulated fuel consumption saving through the column efciency improvement.
Test run data comparison
Table 2
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and two-pass rectifcation
section trays. It is inherently
diffcult to achieve a uniform
liquid-to-vapour traffc ratio
in each section of the three-
pass trays. Moreover, the
original pasteurisation section
trays and the chimney tray
did not equip any feature for
proper fow ratio balancing.
Each chimney pass open area
ratio was not matched to the
neighbouring three-pass tray
pass open area ratio. In order
to improve fow ratio balanc-
ing, the number of passes for
the pasteurisation section
trays was changed from three
to two and a new chimney
tray was installed as per pass
change.
Case study: post revamp
operation review
The pre- and post-revamp
performances are summarised
and compared in Table 2. As
the overall aromatic unit
capacity has been expanded,
the column charge rates are
also increased. Post-revamp
operation verifes that the
refux ratios of the extract and
raffnate column are reduced,
and these reduced refux
ratios eventually contribute to
energy savings in the xylene column reboiler
furnace. Measured furnace fuel consumption as
per the feed rate is substantially improved. Since
the paraxylene recovery unit adsorbent upgrade
also contributes to savings in furnace fuel
consumption, the net energy-saving contribution
of the column modifcations was simulated and
is included in Table 2.
As product quality specifcations are a little
relaxed to maximise the energy saving and
column feed structures are changed, it is neces-
sary to re-evaluate the performance of the
extract and raffnate columns with post-revamp
operating conditions. The column effciency
curves are constructed using post-revamp opera-
tion simulation modelling and compared to the
pre-revamp base modelling curves. Degree of
separation lines between pre- and post-revamp
operations are shown in Figures 5 and 6. The
overall values gained from tray effciency
through simulation modelling are compared in
Table 3.
In Figure 5, the extract column degree of sepa-
ration curves have similar patterns between the
pre- and post-revamp cases. Slightly relaxed
xylene loss and improved tray effciency through
GT-Optim trays contribute to achieving further
refux ratio savings in post-revamp operating
conditions.
It is found that the raffnate column feed
structure is changed in the post-revamp operat-
ing mode. Sensitivity analysis through
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2.2
2.1
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2.3
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Theoretical stage number
Pre-revamp test run
Post-revamp test run
Revamp design
Pre-revamp degree of separation
Post-revamp degree of separation
Figure 5 Extract column sensitivity analysis (pre- and post-revamp)
2.1
2.5
2.4
2.3
2.2
2.0
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Theoretical stage number
Pre-revamp test run
Post-revamp test run
Revamp design
Pre-revamp degree of separation
Post-revamp degree of separation
Figure 6 Rafnate column sensitivity analysis (pre- and post-revamp)
simulation modelling shows that the post-re-
vamp degree of separation line is substantially
shifted by the changed feed compositions, and
the pre-revamp degree of separation line is no
longer applicable. In Figure 6, the post-revamp
degree of the separation curve for the raffnate
column is signifcantly shifted by the new feed
composition. Although tray effciencies are
substantially improved and higher theoretical
stages are achieved, changed feed composition
erodes energy savings. Moreover, pre-
revamp product purities cannot be maintained
in post-revamp operating conditions, therefore
purities are a little relaxed.
The post-revamp economic evaluations are
updated and compared to the revamp target
evaluations.
6
The evaluations are based on 3%
infation, 10% weighted average cost of capital,
15-year depreciation, 1% of the total investment
for maintenance, 22% tax bracket and year
2012 average fuel price. Proftability indexes
are expressed with regards to payback period,
net present value (NPV) and internal rate of
return (IRR). These indices
are shown in Figures 7-9. The
charts show that actual
revamp proftability is better
than expected.
Acknowledgment
The paper is updated from an earlier
presentation given at the AIChE 2013
Spring meetings Distillation Topical
Conference/Kister Distillation Symposium
2013, 29 April-2 May 2013, San Antonio,
Texas.
GT-OPTIM is a mark of GTC Technology.
References
1 Lee S H, et al, Optimize Design for Distillation Feed, Hydrocarbon
Processing, June 2011.
2 Hanson D, et al, High capacity distillation revamps, PTQ,
Autumn 2001.
3 Meyers R, Handbook of Petroleum Rening Processes, McGraw-
Hill Company, 1986.
4 Moczek J S, et al, Control of a distillation column for producing
high-purity overheads and bottom streams, I&EC Process Design
and Development, 1963.
5 Kister H, et al, Sensitivity analysis is key to successful DC5
simulation, Hydrocarbon Processing, October 1998.
6 Largeteau D, et al, Challenges and opportunities of 10 ppm
sulphur gasoline: part 2, PTQ, Q4 2012.
Soun Ho Lee is the Manager of Rening Application for GTC
Technology US LLC, Euless, Texas, and specialises in conceptual
process design, simulation modelling, energy-saving design and
troubleshooting for rening and aromatic applications.
Email: Sounho@gtctech.com
8 Revamps 2013 www.digitalrening.com/article/10008553
Case section Pre-revamp test run Post-revamp test run
Extract column
Rectication section, % Base + 3
Stripping section, % Base + 3
Rafnate column
Pasteurisation section, % Base + 9
Rectication section, % Base + 7
Stripping section, % Base + 6
Overall tray efciency comparison
Table 3
1.5
2.0
1.0
0.5
P
a
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s
0
Revamp
design target
Actual
post-revamp
Figure 7 Protability index
payback period
Revamp
design target
Actual
post-revamp
20
15
10
N
P
V
,

m
i
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n

U
S
$
5
Figure 8 Protability index net
present value
Revamp
design target
Actual
post-revamp
150
100
50
I
R
R
,

%
0
Figure 9 Protability index internal
rate of return
Kwang Gil Min is the Senior Process Engineer for GS Caltex
Corporation, Yeosu, Korea, and specialises in process
engineering/operation services. He has been assigned various
projects in the aromatic complex including reforming, aromatic
extraction and xylenes separation units.
Email: mkk04244@gscaltex.com
www.digitalrening.com/article/1000855 Revamps 2013 9 8 Revamps 2013 www.digitalrening.com/article/10008553

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