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Andrew W. Sloley
VECO USA, Inc.
andrew.sloley@veco.com
Timothy M. Zygula
Houston, Texas
tmz21@hotmail.com
Peter W. Faessler
Sulzer Chemtech Singapore
peter.w.faessler@sulzer.com
Wai Kiong Ng
Sulzer Chemtech Singapore
waikiong.ng@sulzer.com
K. Senthil
Sulzer Chemtech Singapore
k.senthil@sulzer.com
Prepared for
Abstract
Many hydrocarbon separation applications can be improved by vacuum
distillation. The relative volatility of many hydrocarbon binary pairs of
components improves with lower pressure, improving the separation
efficiency. At lower pressures hydrocarbon components vaporize at lower
temperatures, reducing the degradation of products by condensation or
polymerization.
Typically applications of distillation columns in vacuum service include refinery
vacuum columns, ethyl-benzene / styrene distillation, mono- / di – / tri - /
ethanolamine distillation, and oleo chemicals. A review of each of the
applications can provide an insight to the overall picture of designing columns
for vacuum service.
alpha ij = Ki / Kj = Pi / Pj
Pi and Pj are the vapor pressures of components i and j at a given
temperature.
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1.0
0.8 α=5
0.6 α=3
Y
0.4 α=2
0.2 α=1
0.0
Knowing the relative volatility for a system is also useful in determining the
amount of separation possible. A relative volatility of 1.0 indicates that both
components are equally volatile and no separation takes place via normal
distillation. When the relative volatility is low, less than 1.05, separation
becomes difficult because a large number of stages are required. The higher
the relative volatility, the more separable are the two components; this
connotes fewer stages in a distillation column in order to effect the same
separation between the overhead and bottoms products. Lower pressures
increase relative volatilities in most systems.
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One of the few cases where lower pressure does not help distillation is 1,1 –
Di Phenyl Ethane, and 1,2,3,4 – Tetra Ethyl Benzene, as shown in the
attached graph. (9)
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Older refinery vacuum tower designs utilized trays to make the required
separation. Each tower internal has advantages and disadvantages.
In low-pressure systems, packing has been shown to be more efficient, but
proper application is important for fouling services. In high-pressure
distillation applications trays have been shown to be more efficient than
packing. For absorption where equilibrium is not the limiting factor, packing
however can be utilized in high-pressure applications.
Trays have few advantages in refinery vacuum service. Their disadvantages
include lower stage efficiency, higher mean residence time, and higher-
pressure drop. A normal designed tray will have 5-mbar pressure drop per
stage.
The advantages of packing in a refinery vacuum service are;
1. the higher stage efficiency,
2. reduced mean residence time,
3. smaller residence time distribution,
4. and lower pressure drop.
These advantages can increase yield of LVGO and HVGO without the
addition of asphaltenes or metals. Currently most vacuum towers have grids
in the wash section and packing in the HVGO and LVGO sections.
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The challenging part of the Vacuum Column is the wash bed, which removes
the entrained heavy key from the light and intermediate keys. The entrained
heavy key can lead to many fouling phenomena as highlighted by this
example.
The industry average wash bed run length approaches 5 years. The average
life of a wash bed is based on a variety of factors, which include;
These tools are now used extensively throughout the fluid machinery industry.
Three dimensional flow analyses through the utilization of CFD have led
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The key advantage of CFD analysis is that it can be used as a numerical test
bed that can minimize the required prototype testing and other associated
costs for product development. It also offers substantial support to design
optimization of existing configurations as shown in below examples (Elder, et.
al., 2003) (8).
One of the keys to successful design of vacuum systems is the feed inlet
system. Currently there are several options available. A CFD study was
conducted by Wehrli et. al., (4), to evaluate the current systems.
Optimum operation of packed separation columns require even distribution of
liquid films and gas flow. While the role of proper liquid distribution was never
disputed, the vapor initial distribution has been secondary. Its importance
becomes evident as large column diameters and packings with lower pressure
drop are considered.
The purpose of the vapor feed system is to introduce process gas or vapor,
coming for example, from the reboiler into the column and to distribute the
vapor evenly over the whole cross section. To achieve this, the vapor velocity
needs to be reduced over a short distance. At the same time, the inlet should
not unduly block the column cross-section or lead to excessive pressure
drops. For economic reasons, a minimum distance between the nozzle and
the packing is desired.
While major challenges within the CFD field, like simulation of multiphase
flows, await better understanding and models of general applicability, many
problems of lower complexity can now be addressed. The goal of the CFD
study was to determine the uniformity of the vapor velocity profile right under
the lower packing or tray edge.
This is the computational domain and boundary conditions of the CFD Study.
The velocities used in this study were within normal design ranges, F factors
of less than 20.
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Standard inlet
This is a standard radial inlet without a vapor feed inlet device. Typical
guidelines would be to have the first tray three to five time the inlet pipe
diameter above the top of the inlet piping.
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The CFD study results show very high velocities (red) along the opposite wall
from the feed inlet, at a point just below the packing inlet. This would be the
expected result from a standard inlet. The vapor flow in the packing would be
non-uniform and resulted in reduced packing efficiency.
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Orifice Baffle
This is a typical orifice baffle vapor feed inlet device. It is used in many
applications. It has a specially designed channel baffle with lateral opening
and a central orifice.
The orifice baffle design shows high velocities along the opposite wall and
adjacent sidewalls. Once again the vapor distribution is less than optimal, but
slightly better than the first case. The packing efficiency would again be
reduced.
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Vapor Horn
This is a vapor horn feed inlet device that uses the advantage of a tangential
feed entry and wall effects to reduce the vapor feed velocity. This device is
usually applied with flashing streams or high velocity vapor feed carrying a
large disperse liquid fraction. Utilizing this device can reduce the height
requirement to the first tray.
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This is a representation of the vapor horn profile just below the packing. It has
no high velocity red components below the packing inlet, and will lead to
increased packing efficiency.
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The streamlines show improved velocity gradients and a vapor horn should be
utilized when possible on a tangential tower entry.
This is an example of a vacuum tower CFD with the chimney tray included in
the simulation.
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120
100
80
NTS
60
40
20
0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
Reflux Ratio
P=150mbar
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120
100
80
NTS
60
40
20
0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34
Reflux-Ratio
P=400mbar
A special design for overhead condenser and reboiler may be used to reduce
the overall column pressure drop. Some of the advantages of using structured
packing in these applications are as follows:
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Ethanolamine Distillation
Ethanolamine Distillation General Overview
The reaction of ethylene oxide with ammonia renders a mixture of mono-, di-,
and tri-ethanol amines. The maximum production of mono-ethanolamine from
the reactor is 70%. Beyond this maximum restriction on mono-ethanolamine,
the plant may be designed for a wide range in product distribution. This
means that the plant has very high flexibility and production and may be
adapted to changing market demands.
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Fatty Acids
Fatty acids are saturated and unsaturated aliphatic carboxylic acids with
carbon chain lengths in the range of C6 up to C24. An example of a fatty acid
is palmitic acid
Splitting oils and fats produces the fatty acids. Glycerine is also produced as
by product. The split fatty acid is a mixture of fatty acids ranging from C6 to
C18 depending on the type of oil or fat. The pure fatty acid is used as an
important raw material in the manufacture of soaps, washing powder and
other personal care products. So it is important to purify the fatty acid to as
high a purity as possible.
Knowledge of the chemical and physical properties of the fatty acid is one of
the basic prerequisites for the design of distillation column for this service. The
odor and color specification is very important for fatty acid. The boiling points
of fatty acids are very high at atmospheric pressure. Therefore, it is necessary
to distill the fatty acids at high vacuum to reduce the vapor pressure otherwise
the product will degrade at high temperatures. The general schematic flow for
the purification of fatty acid is as follows:
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Glycerol
Low pressure drop, high efficiency sheet metal structured metal and wire
gauze packing is the best combination to insure liquid film distribution of the
packing surface. The liquid film distribution is the key to achieving high
efficiency.
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At liquid loads of less than 10 m3/m2hr, the liquid flows within the wire gauze
(internal flow). For higher loads the liquid flows on the exterior surface of the
wire gauze (external flow) (10)
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Conclusions
This paper presents four aspects of vacuum distillation. First was a review of
vacuum distillation principles. Second was a general overview of vacuum
distillation applications. Third was a review of tower feed inlet devices, which
is very important in vacuum distillation. And finally, in several application
sections, a comparison of trays and structure packing was presented, with the
advantages and disadvantages of each mentioned.
Acknowledgments
The authors are grateful to Sulzer Chemtech for the use of pictures and CFD
results in this paper. We also extend our special appreciations to Dr. M.
Wehrli (Sulzer Chemtech, Switzerland), and Mr. D. Summers (Sulzer
Chemtech, USA) for their invaluable comments and review.
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References
5. Karl Kolmetz, Andrew W. Sloley, Timothy M. Zygula, Wai Kiong Ng, Peter W.
Faessler “Design Guidelines for Distillation Columns in Fouling Service”,
American Institute of Chemical Engineers, The 16th Ethylene Producers
Conference, Section T8005 - Ethylene Plant Technology, Advances in Distillation
Technology for Ethylene Plants, 29 April 2004, New Orleans, Louisiana, USA
6. Seader, J.D. and Ernest J. Henley, “Separation Process Principle”s, John Wiley,
1998
8. Elder, R.L., A., Tourlidakis and M.K., Yates. “Advances of CFD in Fluid Machinery
Design”, Professional Engineering Publishing, UK, 2003
10. Florian Kehrer, Peter Moritz, Mark Pilling, “The effects of perforation in structure
gauze packing” American Institute of Chemical Engineers, 29 April 2004, New
Orleans, Louisiana, USA
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