The recent rapid increase in fuel costs has made many companies re-evaluate the design and operation strategies of processes to reduce the energy consumption in plants. These changes involve increasing capital investment in order to reduce energy operating costs. Since distillation columns are major...
The recent rapid increase in fuel costs has made many companies re-evaluate the design and operation strategies of processes to reduce the energy consumption in plants. These changes involve increasing capital investment in order to reduce energy operating costs. Since distillation columns are major energy consumers in plants, the process design, operating strategies, and control systems of distillation columns has been studied by many researchers. The fractionation units in BTX plants consists in many distillation columns. In this study, the modeling, simulation and optimization of the fractionation units in BTX plants were done by using the commercial process simulator, HYSYS Plant, in order to reduce the operation cost, especially the energy cost, of the plant. The steady-state model was constructed by the MESH equations of the distillation columns. The simulation results of a real fractionation unit, located in Yochun area, were compared with the real operation data collect from the DCS system of the plant. It was found that the simulated temperature profiles were close to the real plant data, and the steady-state simulation of the plant is reliable. To analyse and increase the simulation reliability, the temperature sensitivity analyses of each columns were carried out. Also the process variables which are affected by process disturbances were studied in the energy conservation aspects. Even though the double composition control (DCC) strategy of distillation columns has been consider as an ideal product purity control strategy, DCC has problems of dynamic unstability and cost increment of control equipments. In this work, the alternative control strategy, V/F, R/F ratio control, was applied to the binary benzene column. The results were found that the V/F fixed control had a benefit at the region of the benzene composition is lower than 61%, and the R/F fixed control is over. The optimum location of the feed trays of the column were obtained for single columns and the fractionation unit. The results show that the reboiler heat inputs were decreased by 17.8% and the condenser cooling heat duties were decreased by 12.2%. also the optimization study of the whole fractionation units were carried out to find out the operating conditions for minimum energy cost and maximum annual profits. The results of this study will be used not only for the design of new processes and the construction of control strategies, but also for the revamp of old processes and the assessment of control strategies.
The recent rapid increase in fuel costs has made many companies re-evaluate the design and operation strategies of processes to reduce the energy consumption in plants. These changes involve increasing capital investment in order to reduce energy operating costs. Since distillation columns are major energy consumers in plants, the process design, operating strategies, and control systems of distillation columns has been studied by many researchers. The fractionation units in BTX plants consists in many distillation columns. In this study, the modeling, simulation and optimization of the fractionation units in BTX plants were done by using the commercial process simulator, HYSYS Plant, in order to reduce the operation cost, especially the energy cost, of the plant. The steady-state model was constructed by the MESH equations of the distillation columns. The simulation results of a real fractionation unit, located in Yochun area, were compared with the real operation data collect from the DCS system of the plant. It was found that the simulated temperature profiles were close to the real plant data, and the steady-state simulation of the plant is reliable. To analyse and increase the simulation reliability, the temperature sensitivity analyses of each columns were carried out. Also the process variables which are affected by process disturbances were studied in the energy conservation aspects. Even though the double composition control (DCC) strategy of distillation columns has been consider as an ideal product purity control strategy, DCC has problems of dynamic unstability and cost increment of control equipments. In this work, the alternative control strategy, V/F, R/F ratio control, was applied to the binary benzene column. The results were found that the V/F fixed control had a benefit at the region of the benzene composition is lower than 61%, and the R/F fixed control is over. The optimum location of the feed trays of the column were obtained for single columns and the fractionation unit. The results show that the reboiler heat inputs were decreased by 17.8% and the condenser cooling heat duties were decreased by 12.2%. also the optimization study of the whole fractionation units were carried out to find out the operating conditions for minimum energy cost and maximum annual profits. The results of this study will be used not only for the design of new processes and the construction of control strategies, but also for the revamp of old processes and the assessment of control strategies.
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