ChE 312 Process Synthesis & Design

Individual Assignment 1
Due date: Monday 13th, October 2014, 4 pm

Objectives
The objectives of this assignment are:
1.
2.
3.

To use heuristic methods for separator network synthesis;

To use HYSYS to simulate separation processes;
To assess and interpret the results of software calculations.

The breakdown of marks is as follows:

Task No.

Description

Marks

Heuristic column sequencing

15

Shortcut column design using HYSYS

20

Study sensitivity of the thermodynamic model

15

Rigorous column simulation in HYSYS

25

Sensitivity or design study

25

Total

100

This assignment should be read in conjunction with the Feedback and Marking Sheet.
Note: some marking scales are nonlinear.

Acetone Plant Separation Section

Acetone (CH3-CO-CH3) may be produced by the catalytic, vapour phase
dehydrogenation of isopropyl alcohol (IPA). Typically, the reactor effluent contains
similar amounts of acetone and hydrogen, the main reaction products, as well as a
significant quantity of unreacted IPA and water. Hydrogen is separated from cooled
reactor effluent using a Phase Separation Vessel and a Water Scrubbing Unit (not
required simulating). The separation section of the acetone plant needs to purify the
acetone product to send to storage, and remove the excess water from unreacted IPA
for recycling to the reactor as IPA/water azeotrope. The main elements of the
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separation system are two distillation columns connected in series. In a particular

plant, the separation section receives the following stream from the reaction and
preliminary separation (separator and scrubber) sections:

IPA flowrate: 3.84 kmol/h (based on 90% reactor conversion)

Acetone flowrate: 32.43 kmol/h (based on 90% reactor conversion)
Water flowrate: 37.75 kmol/h (includes scrubbing water)
Pressure: 1.63 bar (abs)
Temperature: 22 OC

Task 1. Heuristic column sequencing

The feed to the separation section needs to be separated into three relatively pure
products acetone, IPA/water azeotrope and water using sequences of simple
(one feed, two product) distillation columns.
(a) Sketch and label all possible flowsheets consisting of simple column
sequences for making these three products.
(b) Apply the four performance-related heuristics for simple column sequencing
given in Lecture 6. What is the preferred sequence according to each heuristic?
What do you conclude? Make sure you clearly show any working.

Task 2. Shortcut column design using HYSYS

Consider a sequence of two columns where the distillate of the first column is the
Acetone product and the bottoms of the first column is fed to the second column,
which recovers IPA/water azeotrope as the distillate and excess water as the bottoms
product. Develop shortcut designs for both columns using Shortcut Distillation units in
HYSYS. The following provisional specifications should lead to columns that are
thermodynamically feasible, but potentially poor in terms of their hydraulics and
economics:
Column 1:
-

Recovery of Acetone in distillate: 99.5% (of Column 1 feed)

Recovery of IPA in bottoms: 99.5% (of Column 1 feed)
Reflux ratio: 1.3Rmin
Condenser pressure: 1.2 bar (abs)
Reboiler pressure: 1.4 bar (abs)

Column 2:
-

Recovery of IPA in distillate: 100% (of Column 2 feed)

Recovery of water in bottoms: 95% (of Column 2 feed)
Reflux ratio: 1.3Rmin
Condenser pressure: 1.2 bar (abs)
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Reboiler pressure: 1.4 bar (abs)

Notes:
-

Use total condensers for both columns;

Use the UNIQUAC property method for initial calculations (correctly predicts
formation of azeotrope at 88 wt% IPA and 12 wt% water).

Demonstrate your initial designs by reporting the following:

(a) A clear HYSYS flowsheet (with white background, and not with default HYSYS
background ) ;
(b) A readable stream table (copied from Workbook and pasted properly in the
report, as discussed) ;
(c) Input Summary1 (copied and pasted in the report).

Task 3. Study sensitivity to the thermodynamic model

For column 1, with the help of shortcut simulations, study the effect of
thermodynamic packages on acetone purity
(a) Briefly explain the issues involved in the selection of property package;
(b) Present the calculation results and state the recommended property package
for highest acetone recovery. Does it agree with the property package used in
Task 2?

Task 4. Rigorous column simulation in HYSYS

Based on the shortcut design from Task 2, develop a rigorous simulation of the first
distillation column. Please try to achieve the Acetone distillate purity of 99.5 wt%. For
your rigorous simulation, report the following:
(a) A clear HYSYS flowsheet (white background only);
(b) A readable stream table (copied from Workbook and pasted properly in the
report, as discussed);
(c) Input Summary;
(d) Specify the best achievable configuration for the desired acetone purity;
(e) Brief presentation and comments on the simulation results. List the factors
that affect acetone recovery. Maximum length is 1 page2

Available in Simulation>> Input Summary.

Page limit for single spacing, excluding reference list. The assignment may be single, 1.5 or doublespaced adjust page limit accordingly. A single reference list can appear at the end of the assignment.
2

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Task 5. Sensitivity or design study

Choose one aspect of the design, simulation or operation of column 1 and examine it
in greater detail. Possibilities include (but not limited to):

Number of stages and best feed stage

Optimum reflux ratio
Column operating pressure and pressure drop
Choice of tray or packing type (and its implications)
Column sizing: diameter and height
Column economics
Other separation methods to achieve Acetone distillate purity of 99.5 wt%.
Some other related topic that you would like to explore. One possibility is an
outline of an advisory system to automate the sequencing of distillation
columns using heuristic and/or algorithmic methods. Please check with your
lecturer to confirm that the topic you have chosen is suitable.

Please choose one aspect only, but examine it in depth. Investigate the topic by using
Aspen HYSYS simulations, professional literature sources, and your knowledge of
distillation. Please state clearly the scope of your investigation, and make sure it is
supported by tables, graphs, input file extracts, referencing, explanations,
justifications, checking, discussion of uncertainties and implications, and
recommendations, as needed. Maximum length is 5 pages3

Page limit for single spacing, excluding reference list. The assignment may be single, 1.5 or doublespaced adjust page limit accordingly. A single reference list can appear at the end of the assignment.
3

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Feedback and Marking Sheet for Individual

Assignment 1
Task 1. Heuristic column sequencing (15 marks)

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Task 2. Shortcut column design using HYSYS (20 marks)

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Task 3. Study sensitivity to the thermodynamic model (15 marks)

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Task 4. Rigorous column simulation in HYSYS (25 marks)

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Task 5. Sensitivity or design study (25 marks)

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