Other Hydrocarbons Presented by Sachin Joshi Licensing Manager - - PowerPoint PPT Presentation

Topic Advances in Distillation for Petrochemicals and Other Hydrocarbons Presented by Sachin Joshi

Licensing Manager GTC Technology US, LLC

Advanced Distillation GT-HIDS℠ (Heat Integrated Differential Separation)

Improving Efficiency in Distillation

What is HIDS ?

• Direct Heat Integration by

Vapor compression

• Low pressure Top Section

(Rectification)

• Low-Low Pressure Bottom

Section (Stripping)

• Maximizes Relative Volatility

Heat Integrated Differential Separation (HIDS)

Propane Feed Propylene

LLP Column LP Column

HIDS Application

• Applicable to close boiling pure component distillation
• Preferentially for C2 to C5 component fractions
• Reduces the CAPEX and OPEX compared to

traditional distillation and Vapor Re-Compression (Heat Pump)

• GTC patent protected

Case Study – C3 Distillation Traditional Process Options:

Mechanical Vapor Re-Compression (VRC) High pressure distillation (HP Distillation)

Case Study - C3 Distillation HP Distillation - Schematic

• Typically Operates at 220

Psig@Top

• Below feed or Bottom Section

(Stripping) operates at higher pressure

• Designed for utilizing cooling water
• Highest Energy for Separation due

to lower relative volatility

Case Study – C3 Distillation Vapor Re-Compression (VRC) - Schematic

• Lower Pressure, typically operates at 160 Psig
• Lower Temperature
• Higher Relative Volatility compared to HP distillation
• Compressor power is determined by reboiler

temperature pinch and overall system ΔP, and

• verflash from hot reflux

Case Study – C3 Distillation Vapor Recompression (VRC)

Effect of Pressure on Relative Volatility

HP Dist. VRC.

1.11 1.115 1.12 1.125 1.13 1.135 1.14 1.145 1.15 1.155 1.16 25 50 75 100 125 150 175 200 225 250

Relative Volatility Pressure in Psig

Relative Volatility of Propylene to Propane

Relative Volatility

Traditional Process Options

• High pressure distillation (HP Distillation)
• Vapor recompression (VRC)

HP Distillation VRC CAPEX

Base Higher than Base

OPEX

Base Lower than Base

• GTC Option

– Heat Integrated Differential Separation

Case Study – C3 Distillation Process Options

GT-HIDS℠ - Heat Integrated Differential Separation

Propane Feed Propylene

LLP Column LP Column

Top Section Bottom Section

Pressure Reducing Valve

GT-HIDS℠ Advantage

• Non linearity of relative volatility is addressed by Pressure Segregation

– Pressure segregation between Stripping (Bottom) and rectification (Top) to optimize relative volatility – Temperature effect on Relative volatility is taken advantage – Significantly improved relative volatility

Relative Volatility Temperature Pinch

• Direct coupling of top (rectification) and bottom (Stripping) section

– Eliminates temperature pinch in the reboiler – Avoids overflash from hot reflux in VRC schemes – Thermally coupled columns reduces the overall energy consumption

GT-HIDS℠ Operating Range for C3 Separation

1.11 1.115 1.12 1.125 1.13 1.135 1.14 1.145 1.15 1.155 1.16 60 80 100 120 140 160 180 200 220 240

Relative Lolatility

Pressure in Psig

Relative Volatility of Propylene to Propane

Rectification Zone (Top Section) Stripping Zone (Bottom Section)

Case Study – C3 Distillation Process Options

1.08E+00 1.10E+00 1.12E+00 1.14E+00 1.16E+00 1.18E+00 1.20E+00 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240

Relative Volatility Stages

Relative Volatility of Traditional Distillation methods & GT-HIDS

HP DIST-RV VRC Dist-RV HIDS Stripping HIDS-Rectification

VRC- FeedPoint HP DIST FeedPoint HIDS - LLP Column - Bottom HIDS LP Column - Top

GT-HIDS℠ Advantages

• Maximizes the natural behavior of components to

separate from each other

• Lower energy compared to traditional distillation

methods

• Distillation done at best relative volatility efficiency point
• Thermally coupled columns consume lower electricity

compared to a VRC

• Independent control of stripping and rectification zones
• ffer stability and ease of operation

Case Study: C3 Distillation Feed Specification Component Mol % Ethane 0.02 % Propane 20.86% Propylene 79.11% i-Butane 0.01%

• Feed Capacity = 30 KBPD

Case Study : C3 Distillation Product Specifications

Propylene specification

• Recovery: 99.87% of

Propylene Propane specification

• Recovery: 98% of

Propane

Component Mol % Ethane 0.02% Propane 0.38% Propylene 99.58% i-Butane 0.01% Component Mol % Ethane 0.01% Propane 99.38% Propylene 0.59% i-Butane 0.02%

Case Study: C3 Distillation Overall Comparison: CAPEX & OPEX

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% CAPEX OPEX HIDS 43% 85% VRC 100% 100%

Cost

• 1. 4Q of 2015

2.Electricity = $0.04 per KW-Hr 3.Cooling water = $0.075 per 1000 gallons

HIDS HIDS MVRC MVRC

C3 Splitter Debottleneck with HIDS

Distillation C3 Splitter C3 Splitter Revamped to GT-HIDS℠

• Capacity Increment: by up to 50%
• Energy Required: less by 40% compared to new system

Propylene Propane Feed Column B Column A New LLP Column New Compressor

C3 Splitter Debottleneck with HIDS

Vapor Recompression C3 Splitter C3 Splitter Revamped to GT-HIDS

• Capacity Increment: by up to 50%
• Energy Required: less by 40% compared to new system

Propylene Propane Feed Column A New LLP Column

Dividing Wall Columns

Improving Fundamental Efficiency in Distillation

Case Study: Grassroots Mixed Xylenes Recovery Unit at a Refinery in Japan

• TG had an existing unit which produced C7+ product for

gasoline blending.

• TG wanted to separate high purity petrochemicals (Toluene,

Mixed Xylenes) from the feed.

• TG decided for a DWC solution against a two column

configuration because of lower CAPEX and lack of plot space.

Case Study: Mixed Xylenes Recovery

GT-DWC℠ for Mixed Xylenes Recovery

Comparison: Two Column System vs DWC

Parameter Units Two Column Configuration GT-DWC℠ Configuration Mix-xylenes product Kg/hr 29,332 29,334 C8 aromatics wt%. 99.2 99.3 Reboiler duties MMkcal/hr. 21.6 17.2 Operating cost savings %

• 20.0

Capital cost US $ MM 26.0 21.0 Steam savings due to heat integration TPH

• 20.0

TonenGeneral Mixed Xylenes Recovery Unit

• Installation of GT-DWC℠ Column at Chiba Refinery, Japan
• Column Operational since March 2016

GT-DWC℠ Internals Manufacturing - Korea

GT-DWC℠ Trays Testing of GT-DWC℠ Internal Liquid Split Distributer

Summary

• Advanced distillation applications are an overlooked

means to reduce refinery energy consumption – GT-DWC reduces 20–30% OPEX through energy savings – GT-DWC reduces 20–30% CAPEX by requiring a single column for multi-component separation

• GT-HIDS can make significant energy reduction

and/or capacity enhancement with simpler modifications.

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GTC Technology

DISTILLATION