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Research Article
Optimize distillation column design for improved reliability
in operation and maintenance
Karl Kolmetz,1 * Wai Kiong Ng,1 Siang Hua Lee,1 Tau Yee Lim,1 Daniel R. Summers2 and Cyron Anthony Soyza3
1
Sulzer Chemtech, Regional Headquarters, 10 Benoi Sector, SG-629845, Singapore
2
Sulzer Chemtech, 4019 S. Jackson Avenue, US-Tulsa, OK 74107, USA
3
Phoenix Training and Development Centre, Johor Bahru, Malaysia
ABSTRACT: A distillation tower design is normally made in two steps; a process design, followed by a mechanical
design. The purpose of the process design is to calculate the required stream flows and number of required theoretical
stages. Required steam flows could include reflux rate, side draws, and the heat duties (number of pump arounds and
the condenser and reboiler). The purpose of the mechanical design is to select the tower internals, column diameter
and height.
The process and mechanical designs can be completed very quickly utilizing cook book procedures that many
Engineering Procurement and Construction (EPC) firms have established. Often the cook book designs can be
optimized for improved profitability, operations and maintenance.
The best way to review profitability is the life cycle cost, which is the initial capital cost of the plant along with the
first 10 years operating and maintenance cost. The life cycle cost includes a reliability factor, which is very important
in designing any process plant equipment. Improved reliability has a very large impact on return on investment (ROI).
Several factors should be considered when designing distillation equipment;
This review will include general distillation design guidelines applicable to any process along with specifics for the
natural gas processing, refining, petrochemicals, and the oleo chemicals industries. 2007 Curtin University of
Technology and John Wiley & Sons, Ltd.
INTRODUCTION cost of the plant along with the first 10 years operating
and maintenance cost. The life cycle cost should include
There are many separation processes and each one has a reliability factor, which is very important in designing
its best application. They include distillation, crystal- any process plant equipment, reactors or separation
lization, membrane, and fixed bed absorption systems.
equipment. Improved reliability has a very large impact
Occasionally the best system may be a combination of
these systems. on return on investment (ROI). Many life cycle cost
The choice of the best application should be based on only review energy, but not solvent, adsorbent, or
the life cycle cost. The life cycle cost is the initial capital catalyst cost because of accounting rules and this can
lead to skewed economic decisions.
*Correspondence to: Karl Kolmetz, Sulzer Chemtech Pte Ltd., Distillation may be the most economical and is the
Regional Headquarters, 10 Benoi Sector, SG-629845, Singapore. most utilized globally to obtain improved purity prod-
E-mail: kkolmetz@yahoo.com
points. It can also be called fractional distillation or frac- fouling service because it has no horizontal surfaces,
tionation. Distillation is favored over other separation but if the process has high maintenance concerns,
techniques such as crystallization, membranes or fixed random packing may be chosen to reduce the life cycle
bed systems when; cost. An example of this is caustic towers in Ethylene
plants.
1. The relative volatility is greater that 1.2,
2. Products are thermally stable,
3. Large rates are desired,
4. No extreme corrosion, precipitation or sedimentation General rules of thumb
issues are present,
5. No explosion issues are present, The first general rule of thumb is to review the common
6. Low scale up cost factors capacity can be doubled industry practice for your particular process. This will
for about 1.5 additional cost, give you a guide in which to start your selection process,
7. Suitable for heat integration. but in a competitive environment the lowest initial cost
may be the most widely utilized, but may not be the best
overall option. Rules of thumb will have exceptions and
may only apply about 90% of the time.
THE CORRECT DISTILLATION EQUIPMENT
FOR THE PROCESS CONDITIONS Packing rules of thumb
Packing should be utilized when;
There are many types of processes that are grouped
together and called distillation. Most have similarities, 1. Compounds are temperature sensitive
but some have noticeable differences. A partial list of 2. Pressure drop is important (vacuum service)
the distillation grouping includes; 3. Liquid loads are low
4. Towers are small in diameter
1. Distillation
5. Highly corrosive service (use plastic or carbon)
2. Absorption
3. Stripping 6. The system is foaming
4. Extractive distillation 7. The ratio of tower diameter to random packing size
5. Reactive distillation is greater than 10.
6. Azeotropic distillation
7. Batch distillation Tray rules of thumb
Trays should be utilized when;
There are several choices of distillation equipment for
each of these operations. The choice of which to uti- 1. Compounds containing solids or foulants
lize depends on the (1) pressure, (2) fouling potential, 2. Many internal transitions
(3) liquid to vapor density ratio, (4) liquid loading, and 3. Liquid loads are high
most important (5) life cycle cost. Distillation equip- 4. Lack of experience in the service
ment includes many categories of equipment. The two 5. Vessel wall needs periodic inspection
major categories are trays and packing, but each of these 6. Multiple liquid phases including water
categories has many divisions.
Tray divisions include; Tower rules of thumb
1. Maintain 1.2 m at the top for vapor disengagement,
1. Baffle trays 2. Maintain 2 m at the bottom for liquid level and
2. Dual flow trays reboiler return,
3. Convential trays 3. Limit tower heights to 60 m because of wind load and
4. High capacity trays foundation concerns,
5. Multiple downcomer trays 4. The length to diameter ratio should be less than 30,
6. System limit trays 5. Reflux drums should be horizontal with a liquid
residence time of 10 min.,
Packing divisions include; 6. Gas/liquid separators are vertical,
1. Grid packing 7. If the reflux drum has a second liquid phase, such as
2. Random packing water, the second phase should have a linear velocity
3. Convential structured packing of 150 mm/sec and not smaller than 400 mm,
4. High capacity structured packing 8. Utilize a water boot for small amounts of water
accumulating in a reflux drum
There are both process and economic arguments 9. Optimum pressure vessel length to diameter ratio is 3
for the best choices in equipment selection. Typically 10. Choose materials of construction to reduce corrosion
structured packing is better than random packing for issues,
2007 Curtin University of Technology and John Wiley & Sons, Ltd. Asia-Pac. J. Chem. Eng. 2007; 2: 294307
DOI: 10.1002/apj
296 K. KOLMETZ ET AL. Asia-Pacific Journal of Chemical Engineering
Designing mass transfer equipment for fouling service Life cycle cost should include total operating cost for
requires first an understanding of the fouling mech- the first 10 years of operation. Accounting rules which
anism, the process in which the fouling occurs, and list some items as capital cost and other items as
behavior of the process when the fouling is present. operating expense need to be totaled or a skewed life
An understanding of these items needs to be developed cycle cost can be generated. A partial list would include;
in advance of designing mass transfer equipment for 1. Capital
fouling service. 2. Catalyst
The challenges of operating fouling columns can 3. Solvents
result in; 4. Energy
5. Maintenance
1. Increase energy consumption due to heat transfer and
6. Industry average on stream factor (95% 20 days
efficiency issues.
per year)
2. Reduced column capacity, which may lead to pro-
duction loses. For distillation the largest life cycle cost would
3. Increased down time for cleaning and disposing of be energy and maintenance concerns. Distillation is
fouling wastes typically the single largest consumer of utilities in a
4. Potential need for the use of chemical additives chemical plant or refinery, and also the largest producer
of finished product in most facilities. For energy cost a
review of tray and packing efficiencies is warranted. For
Vapor to liquid density ratio maintenance cost a review of reliability and simplicity
is warranted.
When structured packing was first introduced, the
vapor to liquid density ratio was not understood, and
structured packing was applied in areas of low vapor CORRECT EQUIPMENT SELECTION FOR
to liquid density with unexpected results. In one case EXPECTED RUN LENGTH
an Alky Unit DeIsoButanizer was revamped from trays
to rings with less performance, the original trays were Hydrocarbon producers are exploring avenues to extend
then reinstalled. Several propylene and ethylene splitters the on-stream time between outages for maintenance.
were revamped to structured packing, and then had trays Key equipment that can determine the end of run
re-installed. includes: catalyst life, cyclone erosion, and compressor
Trayed column are also affected by the vapor to and tower fouling. Critical equipment that has been
liquid density ratio. The down comer capacity is directly shown to be a limiting factor can be duplicated to
affected by the ability of the liquid vapor mixture ability extend run length: for example parallel pumps, reactors
to separate into their respective phases. At low vapor and reboilers. This is a successful method to extend
to liquid density ratios this can be difficult if the down on-stream time, though it is expensive and in fact, at
comers are not sized properly. times cost prohibitive. Incorporating design guidelines
2007 Curtin University of Technology and John Wiley & Sons, Ltd. Asia-Pac. J. Chem. Eng. 2007; 2: 294307
DOI: 10.1002/apj
Asia-Pacific Journal of Chemical Engineering OPTIMIZE DISTILLATION COLUMN DESIGN FOR IMPROVED RELIABILITY 297
The top causes of damage in vacuum tower include Olefins unit application example
Because humans are less sensitive to pressure than Refinery unit application example
temperature, we measure pressure in large units. In the
ideal gas law PV = nRT, pressure is measured in units It is not unusual for operation to run a piece of
of 1 bar and temperature in units of degrees Kelvin, equipment at higher levels if there is a low level
therefore temperature measures will be much more shutdown, or if the process feeds a multistage pump.
accurate than pressure measurements. Control strategies Caution needs to be taken and this phenomena need to
that rely strongly on pressure will be less stable than be understood or a tower reboiler return can be blowing
those that rely on temperature. into the liquid level, resulting in entrainment to the first
Of the 37 listed DeButanizer malfunctions, the most tray. If there is a steam sparger in the tower bottoms as
common malfunctions are widely different from those in found in refinery atmospheric crude towers, care must
vacuum, crude and FCC fractionators. Ten of the thirty- be taken to insure the sparger is above the liquid level.
seven were in process control, and five of them were In one example a refinery atmospheric crude tower
with pressure and condenser controls. The challenge of was revamped and the steam sparger was lowered.
DeButanizer condenser is with the noncondensables that During crude feed changes the tower bottoms level can
the previous towers might not totally remove. be higher than normal resulting in the steam sparger
For packed towers the key fouling factors revolve Dual flow trays are the trays of preference for heavy
around liquid distribution and packing residence time. fouling services, but have low stage efficiency. Dual
The longer the residence times the less suitable. Low- flow trays have no down comers, where products of
pressure drop, smooth surface, low residence time fouling phenomena can accumulate. Stagnation in a
packings perform best in fouling service. The order of down comer, or even on a tray deck, due to back mixing,
preference is: can result in polymer formation.
The vapor and liquid transfers up and down the
column thru the holes on the tray deck. This is an
1. Grid advantage if the fouling is in the vapor state as the under
2. Structured packing side of the tray is continually washed. The continuous
3. Random packing agitation of the liquid on the topside of the trays
combined with continuous underside wetting/washing
action makes this tray suitable for fouling services. The
Packing distributor concerns challenge of the dual flow tray is maldistribution in
larger diameter towers.
In fouling service, distributors are areas where residence Two types of dual flow trays are available; standard
time is increased and fouling phenomena can occur. deck and rippled deck. The standard deck has is a
In high-fouling services trough v-notch or other type flat plate, and the rippled deck has sinusoidal waves.
2007 Curtin University of Technology and John Wiley & Sons, Ltd. Asia-Pac. J. Chem. Eng. 2007; 2: 294307
DOI: 10.1002/apj
300 K. KOLMETZ ET AL. Asia-Pacific Journal of Chemical Engineering
Levelness is of extreme importance to dual flow trays maximum production of mono-ethanolamine from the
because the liquid will migrate to the low level on reactor is typically 70% (Fig. 4). Beyond this maximum
the tray and start channeling. Dual flow trays have a restriction on mono-ethanolamine, the plant may be
tendency for harmonic tray vibrations; rippled decks designed for a wide range in product distribution. This
have an excellent record in fouling service except for means that the plant has very high degree of flexibil-
one recent documented case. ity and production may be adapted to changing market
demands.
The reaction of ethylene oxide with ammonia renders Figure 4. Ethanolamine production. This figure is available
a mixture of mono-, di-, and tri-ethanol amines. The in colour online at www.apjChemEng.com.
2007 Curtin University of Technology and John Wiley & Sons, Ltd. Asia-Pac. J. Chem. Eng. 2007; 2: 294307
DOI: 10.1002/apj
Asia-Pacific Journal of Chemical Engineering OPTIMIZE DISTILLATION COLUMN DESIGN FOR IMPROVED RELIABILITY 301
Liquid Head
Froth
Tray
V = Hole Velocity
Vc = 23(LV)HCL FP/(C(V0.5))
C = 2.0 CH gCW/12.0
Demister pads
Figure 9. Typical demister pad issues. This figure is available
Demister pads (Fig. 8) are very easy to design and in colour online at www.apjChemEng.com.
install, but tend to be high maintenance issue items.
Typical entrainment removal of 99% can be obtained
which list some items as capital cost and other items
with 150 mm (6 inches) of mesh pads. There have
as operating expense need to be totaled or a skewed
been numerous failures in demister pad systems due to
life cycle cost can be generated. A partial list would
pressure surges (Fig. 9). The pad may foul with material
include;
and fail due to pressure drop increases.
1. Capital
2. Catalyst
EVALUATION OF THE MOST COST EFFECTIVE 3. Solvents
SOLUTION FOR MINIMUM LIFE CYCLE COST 4. Energy
5. Maintenance
The best way to review profitability is the life cycle cost, 6. Industry average on stream factor (95% 20 days
which is the initial capital cost of plant along with the per year)
first 10 years operations and maintenance cost. The life
cycle cost includes a reliability factor, which is very For distillation the largest life cycle cost would be
important in designing any process plant equipment. energy and maintenance concerns.
Improved reliability has a very large impact on ROI.
Life cycle cost should include total operating cost Factors that increase life cycle cost
for the first 10 years of operation. Accounting rules Several factors that increase life cycle cost include;
2007 Curtin University of Technology and John Wiley & Sons, Ltd. Asia-Pac. J. Chem. Eng. 2007; 2: 294307
DOI: 10.1002/apj
Asia-Pacific Journal of Chemical Engineering OPTIMIZE DISTILLATION COLUMN DESIGN FOR IMPROVED RELIABILITY 303
1. The need for very high or very low temperatures, will inherently have a lower level of efficiency perfor-
less that 40 C or greater than 250 C mance. Generally, higher capacity devices exhibit lower
2. Small concentrations of high boiling contaminants efficiency. The reason for this is that the contact time
must be removed high energy. between the liquid and the vapor is greatly reduced at
3. High operating flexibility for seasonal or market higher throughput.
conditions
4. Low stage efficiency
5. Exotic materials of construction Design of trays to improve efficiencies and
6. Low instrumentation reliability capacities
baffle bar
Figure 10. Liquid flow on trays. This figure is available in colour online at
www.apjChemEng.com.
2007 Curtin University of Technology and John Wiley & Sons, Ltd. Asia-Pac. J. Chem. Eng. 2007; 2: 294307
DOI: 10.1002/apj
304 K. KOLMETZ ET AL. Asia-Pacific Journal of Chemical Engineering
Opening size
There is an optimum bubble size, therefore an optimum
opening size. Too small or too large can effect the size
of the bubble, leading to loss of efficiency. Here is the
normal trade off between capacity and efficiency.
20
Exotic materials of construction 0
The choice of materials of construction can have a 0 20 40 60 80 100 120
profound effect on the performance of a unit if corrosion Liquid Height (mm)
sets in. The engineer is constantly striving to produce
an economical design with the least expensive materials. Figure 12. Weir Height versus efficiency. This figure is
available in colour online at www.apjChemEng.com.
However, there are minimum specifications on the types
of materials to be used in common services to ensure
minimal corrosion or stress cracking. Some of these are:
Oleo chemical application example divided
wall columns versus side strippers for fatty acid
Hydrocarbons (no H2S) Carbon steel (A-569) distillation
temp >40 C An oleo chemical application example for life cycle
Hydrocarbons (no H2S) Killed carbon steel cost would be to compare a conventional column with
temp 30 to 40 C side strippers verses a divided wall column. A dis-
Hydrocarbons (no H2S) 3 1/2 Nickel steel tillation column may be required to process different
temp 100 to 30 C (SA-203) feedstocks and produce different products simultane-
Hydrocarbons (no H2S) 304L Stainless steel ously. Divided wall columns have been proposed, but
temp <100 C few applications have been proven in the oleochemcial
Acetic acid 316L Stainless steel or industry.
titanium The main advantages of divided wall columns
Chloride service Duplex 2205 or (Fig. 14) include;
Hastelloy C-276
Chlorine & HCl service Nickel 200 or tantalum 1. Two columns combined in one shell
Ethanol 304L Stainless steel 2. Decreased energy requirements
Methanol Carbon steel and 304L 3. Production of three products
Stainless steel 4. Creation of a prefractionator on the feed side
5. Avoid remixing of products
2007 Curtin University of Technology and John Wiley & Sons, Ltd. Asia-Pac. J. Chem. Eng. 2007; 2: 294307
DOI: 10.1002/apj
Asia-Pacific Journal of Chemical Engineering OPTIMIZE DISTILLATION COLUMN DESIGN FOR IMPROVED RELIABILITY 305
C10 FREE
COCONUT
OIL FA
10,000 kg/h
Max. 0.4%
C14 FA
Figure 13. Case one conventional two-column system. This figure is available in colour
online at www.apjChemEng.com.
1. Low capital cost theoretical stages, packing heights, pressure drop etc.
2. Reasonable energy consumption on capital and operating cost.
3. Ease of installation
4. Stable flexible operation
5. Good performance if middle distillate is in lower CONCLUSIONS
concentration
6. Decreased operational and maintenance complexity
An engineers function is to find the most economical
7. Possibilities to revamp single column and add new
solution to a complex problem. The optimum design
side strippers
guidelines as presented here describe a way to achieve
Disadvantages of single column with side stripper: this end through consideration of the life cycle cost. The
authors trust that the information contained here in has
1. Increased pressure drop been of help in determining the lowest life cycle cost
2. Increased column diameter of their separations needs.
3. Slightly larger space requirements
A comparison of the three cases (Table 1) is based
REFERENCES
on individually optimized detailed process simulations
and consequent plant designs, incorporating different Kister HZ. Distillation Design. McGraw-Hill Book Company Inc.:
aspects like the impacts on the required number of New York, 1992.
C12 99%
4,851 kg/h
C10 FREE
COCONUT
OIL FA
Max. 0.4%
C14 FA
5,149 kg/h
Figure 15. Case 3 single column with side stripper. This figure is available
in colour online at www.apjChemEng.com.
Two column system case 1 Divided wall column case 2 Column with side stripper case 3
Purity Same Same Same
Capacity (%) 100 100 100
Column diameter (m) 2.1/1.5 2.8 2.7/2.3 + 1.5
Overall capital cost 100 70 80
Energy consumption (kW) 1690 (100%) 2115 (125%) 1882 (108%)
Life cycle costa 100 94.8b 87.6
a
Based on USD 170 per tons of fuel gas and current capital investment cost indexes.
b
Without consideration of operational flexibility (processing different feedstock).
2007 Curtin University of Technology and John Wiley & Sons, Ltd. Asia-Pac. J. Chem. Eng. 2007; 2: 294307
DOI: 10.1002/apj
Asia-Pacific Journal of Chemical Engineering OPTIMIZE DISTILLATION COLUMN DESIGN FOR IMPROVED RELIABILITY 307
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2007 Curtin University of Technology and John Wiley & Sons, Ltd. Asia-Pac. J. Chem. Eng. 2007; 2: 294307
DOI: 10.1002/apj