산업공정에서 분리벽형 증류탑의 설계와 최적화 : Design and Optimization of Dividing Wall Column for Process Industry|RISS 상세보기

국문 초록 (Abstract)

분리벽형 증류탑은 상당한 에너지를 감소 시킬 수 있는 매우 유망한 기술이다. 간단한 shell형태의 증류는 3가지 이상의 물질을 높은 순도의 생산물을 분리 할 수 있게 해준다. 그러나 분리벽형 증류탑(DWC)의 설계는 많은 자유도를 가지기 때문에 기존의 방식보다 더 복잡하다. 이 변수들은 서로 상호관계에 있으며 일괄적인 최적화를 통해서 가장 적합한 구조를 찾는다. 최적화 방법으로는 반응표면분석법(RSM)과 요인분석적 설계법(factorial design)을 사용한다. 이러한 방법을 통한 최소한의 공정모사로 분리벽형 증류탑의 최적화된 구조를 찾을 수 있다.
분리벽형 증류탑 구조는 지상과 해상의 NGL회수공정에 적용하여 공정의 효율을 향상 시킬 수 있다. 일반적인 분리벽형 증류탑(CDWC)과 탑정형 분리벽 증류탑(TDWC) 그리고 탑저형 분리벽 증류탑(BDWC)을 통하여 모사한 결과 공정 시스템에 많은 이점들을 제공하였다. 예를 들면 냉각비용을 포함한 운전비용과 재비기와 응축기의 열 소비량을 기존의 공정에 비해 절감할 수 있었다. 또한, 분리벽형 증류탑의 효과를 더욱 증가 시키기 위해 탑 상부의 열을 통합하고 중간 재비기 시스템을 탑 하부에 설치하였다. 또한 이번 연구에서 에너지 효율 향상을 위해 탑저형 분리벽 증류탑과 열 펌프와의 다양한 결합구조가 제안되었다. 그 결과 증류탑의 내•외부의 새로운 열 통합을 통해 운전비용을 감소 시킬 수 있었다 : 탑저형 분리벽 증류탑은 탑 상부의 기체를 재 압축하는 열 펌프 혹은 부분 하부 훌래쉬 열 펌프가 쓰인다. 에너지 효율을 향상시키기 위해 이중배열 예비 분리기(DPA)와 이중 배열 분리벽형 증류탑을 포함하는 새로운 복잡한 형태의 배열들이 제안 되었다.
추가적으로 이번 연구는 증류탑의 측면을 개조하는 것과 분리벽형 증류탑의 구조 그리고 측면 정류기를 포함하는 열 결합형 증류배열(TCEDS-SR)에 의해 에너지가 절감 된다는 것을 보여준다.
이는 기존의 증류탑을 활용하여 분리벽형 증류탑과 열 결합형 증류배열(TCEDS-SR)로 개조할 수 있을 뿐만 아니라 이로 인해 공정의 수용력을 증가 시킬 수 있다는 것을 보여준다.
분리벽형 증류탑은 처리량 증가에 따른 증류탑의 병목현상을 제거하기 위해 사용되기도 한다. 여러가지 실험을 통해 분리벽형 증류탑을 사용하는 것이 병목현상의 제거와 투자비용, 에너지 소비량을 절감 할 수 있다는 것을 보여주기 위해 분석되었다.

번역하기

분리벽형 증류탑은 상당한 에너지를 감소 시킬 수 있는 매우 유망한 기술이다. 간단한 shell형태의 증류는 3가지 이상의 물질을 높은 순도의 생산물을 분리 할 수 있게 해준다. 그러나 분리벽...

다국어 초록 (Multilingual Abstract)

Dividing wall columns (DWCs) represent a very promising technology allowing a significant energy requirement reduction. It is a simple shell, capable of separating mixtures of three or more components into high purity products. However, the design of DWCs is more complex than conventional arrangements because of the greater number of degrees of freedom. These variables interact with each other and need to be optimized simultaneously to obtain the best design. Thus, practical methods employing response surface methodology (RSM) and factorial design are proposed for DWC design and optimization. The optimum DWC structure can be found in a practical manner while minimizing simulation runs. They effectively cope with interactions between optimizing variables and their predictions agreed well with the results of rigorous simulation.
Furthermore, the application of dividing wall column is focused to improve the performance in NGL recovery process for both onshore and offshore plants. The results show that the conventional DWC (CDWC), top DWC (TDWC), and bottom DWC (BDWC) can offer many benefits to the system, e.g. decreasing the operating cost including refrigeration cost, and minimizing the reboiler and condenser duty. Furthermore, to further enhance the dividing wall column performance, heating is integrated on the top and an interreboiling system is installed at the bottom section of the dividing wall column. In this study, various configurations incorporating a heat pump in a bottom diving wall columns are also proposed to enhance energy efficiency further. The result showed that operating cost could be reduced most significantly through novel combinations of internal and external heat integration: bottom dividing wall columns employing either a top vapor recompression heat pump or a partial bottom flashing heat pump. New complex distillation arrangements, including the double prefractionator arrangement (DPA), and the double dividing wall column arrangement (DDWC) are also proposed to improve energy efficiency.
In addition, this work shows that energy saving can be obtained by retrofit the side distillation column and extractive distillation sequence to a dividing wall column and a thermally coupled extractive distillation (TCEDS-SR) with small modification. Retrofit to a DWC and a TCEDS-SR could not only exploit the existing columns, but also increase the process capacity.
The systematic identification and design of column sequences involving the DWC is applied for removing the column bottleneck problem due to throughput increase. Several cases are analyzed to show that use of the dividing wall column is a promising method for debottlenecking, as well as investment cost and energy consumption saving.

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목차 (Table of Contents)

Chapter 1 Introduction 1
1.1. Motivations 1
1.2. Contributions of the Thesis 8
1.3. Thesis Outline 8
1.4. References... 11

Chapter 1 Introduction 1
1.1. Motivations 1
1.2. Contributions of the Thesis 8
1.3. Thesis Outline 8
1.4. References... 11
Part I: Design and Optimization 17
Chapter 2 Dividing Wall Column Structure Design Using Response Surface Methodology 19
2.1. Introduction 19
2.2. Design and Optimization Methodology 22
2.2.1 Design 22
2.2.2 Optimization 22
2.3. Case Study. 24
2.3.1 Conventional Distillation Sequence 24
2.3.2 Dividing Wall Column 26
2.4. Conclusions... 31
2.5. References... 31
Chapter 3 Design and Optimization of a Dividing Wall Column by Factorial Design 36
3.1. Introduction 36
3.2. Design and Optimization Methodology 37
3.2.1 Design 37
3.2.2 Optimization 38
3.3. Case Study. 39
3.3.1 Case 1 – Debutanizer and Deisobutanizer 39
3.3.1.1 Conventional Distillation Sequence 39
3.3.1.2 Dividing Wall Column 41
3.3.2 Case 2 – Depropanizer and Debutanizer 45
3.3.2.1 Conventional Distillation Sequence 45
3.3.2.2 Dividing Wall Column 47
3.4. Conclusions 49
3.5. References... 50
Part II: Application – Integration 53
Chapter 4 Improvement of the Deethanizing and Depropanizing Fractionation Steps in NGL Recovery Process Using Dividing Wall Column 54
4.1. Introduction 55
4.2. Conventional Distillation Sequence. 55
4.3. Integrating Using CDWC 59
4.3.1 Conventional Dividing Wall Column (CDWC) 59
4.3.2 Heat Integrated DWC 65
4.4. Integrating Using TDWC 66
4.4.1 TDWC 66
4.4.2 Heat Integrated TDWC 70
4.5. Conclusions 71
4.6. References... 72
Chapter 5 Design and Optimization of Heat Integrated Dividing Wall Columns for Improved Debutanizing and Deisobutanizing Fractionation of NGL 73
5.1. Introduction 74
5.2. Design and Optimization Methodology 76
5.2.1 Design 76
5.2.2 Optimization 77
5.3. Case Study 78
5.3.1 Conventional Distillation Sequence 78
5.3.2 Conventional Dividing Wall Column (CDWC) 80
5.3.3 Bottom Dividing Wall Column (BDWC) 85
5.3.4 BDWC with Top Vapor Recompression Heat Pump 87
5.3.5 BDWC with Bottom Flashing Heat Pump 89
5.3.6 BDWC with Partial Bottom Flashing Heat Pump 90
5.3.7 Multi-Effect Prefractionator Arrangement 91
5.4. Conclusions 94
5.5. References... 94
Chapter 6 Improvement of Natural Gas Liquid Recovery Energy Efficiency through Thermally Coupled Distillation Arrangements 98
6.1. Introduction 99
6.2. Conventional Distillation Sequence. 102
6.3. Proposed Arrangements 105
6.3.1 Integrating Debutanizer and Deisobutanizer Using a Dividing Wall Column 105
6.3.2 Integration by the Double Prefractionator Arrangement 108
6.3.3 Integration by the Double Dividing Wall Column 109
6.3.4 Integration by the Agrawal Arrangement 112
6.4. Conclusions 113
6.5. References... 115
Chapter 7 Design and Optimization of Natural Gas Liquid Recovery Process for Offshore Floating LNG Plant 118
7.1. Introduction 119
7.2. Comparison of Onshore LNG and Offshore FLNG Plants 121
7.3. NGL Recovery 124
7.3.1 Proposed Base Sequence 124
7.3.2 Improvement of Proposed Base Sequence 127
7.3.2.1 Feed Split 127
7.3.2.2 Top Dividing Wall Column (TDWC) 128
7.3.2.2.1 Optimization Methodology 129
7.3.2.2.2 TDWC Configuration 130
7.4. Integration of Natural Gas Liquefaction and NGL Recovery 133
7.5. Conclusions 135
7.6. References... 136
Part III: Application - Retrofit 140
Chapter 8 Energy Efficiency Maximization through Optimal Side Stream Column Retrofit 141
8.1. Introduction 142
8.2. Design and Optimization Methodology. 144
8.2.1 Design 144
8.2.2 Optimization Methodology 146
8.2.2.1 Factorial Design 146
8.2.2.2 Response Surface Methodology 147
8.3. Case Study 148
8.3.1 Existing Side Distillation Column 148
8.3.2 Dividing Wall Column 150
8.3.2.1 Retrofit Using Factorial Design 150
8.3.2.2 Retrofit Using Response Surface Methodology 153
8.4. Conclusions 158
8.5. References... 158
Chapter 9 Optimal Retrofit Design for Improving Energy Efficiency of Extractive Distillation 162
9.1. Introduction 163
9.2. Design. 167
9.3. Optimization 167
9.4. Case Study 168
9.4.1 Mixture M1 169
9.4.2 Mixture M2 175
9.5. Conclusions 179
9.6. References... 180
Part IV: Application - Debottlenecking 184
Chapter 10 Improved Energy Efficiency in Debottlenecking Using a Fully Thermally Coupled Distillation Column 185
10.1. Introduction 186
10.2. Debottlenecking Method 186
10.2.1 Definition and Assumptions 186
10.2.2 Configurations Explored for Debottlenecking 187
10.2.3 Hydraulic Performance Indication and Bottleneck Phenomenon Determination 190
10.2.4 Structure Design 191
10.2.5 Optimization 192
10.3. Case Study 193
10.3.1 Natural Gas Liquid (NGL) Recovery Process 193
10.3.1.1 Existing Process 193
10.3.1.2 Proposed Modification 196
10.3.2 Acetic Acid Purification Process 200
10.3.2.1 Existing Process 200
10.3.2.2 Proposed Modification 201
10.3.3 Methanol – Acetone Separation Process 203
10.3.3.1 Existing Process 203
10.3.3.2 Proposed Medification 204
10.4. Conclusions 206
10.5. References... 206
Chapter 11 Design and Optimization of a Dividing Wall Column for Debottlenecking of the Acetic Acid Purification Process 210
11.1. Introduction 211
11.1.1 Existing Process Configuration 212
11.1.2 Existing Column Hydraulics 214
11.2. Increasing Daily Production 215
11.3. Proposed Modifications 219
11.3.1 Conventional Column Sequence 219
11.3.1.1 Case 1.1 – Adding Two New Columns 219
11.3.1.2 Case 1.2 – Replacing C-304 and Adding One New Column 220
11.3.2 Re-arranging the Existing Column into a Complex Arrangement 222
11.3.2.1 Case 2.1 - Re-arranging the Existing Column into a Petlyuk Column Arrangement 222
11.3.2.2 Case 2.2 - Re-arranging the Existing Column into a Prefractionator Arrangement 222
11.3.3 Debottlenecking Using Dividing Wall Column 225
11.3.3.1 Case 3.1 - Replacing the Two New Columns with a New DWC 225
11.3.3.2 Case 3.2 – Re-traying C-304 and Adding a New DWC in Parallel with C-304 229
11.3.3.3 Case 3.3 – Adding a New DWC in Series 230
11.3.3.4 Case 3.4 – Retrofitting C-304 to a DWC and Adding a New Parallel DWC 232
11.3.3.5 Case 3.5 – Retrofitting C-304 to a DWC and Adding a New DWC in Series 232
11.4. Conclusions 236
11.5. References... 236
Chapter 12. Conclusions and Further Work 237
12.1. Conclusions 238
12.2. Further Work... 240
12.2.1 Systematic Synthesis 240
12.2.2 Reactive Dividing Wall Column (RDWC), Extractive Dividing Wall Column (EDWC), Hybrid Membrane Distillation (MD), and Internal Heat Integrated Distillation columns (HIDiC) 241
12.2.3 Dynamic Simulations and Control 241
12.2.4 Floating LNG 242
12.2.5 Polysilicon – Trichlorosilane (TCS) 242
12.2.6 Experiment 242
Nomenclature 243
Appendix A. Column Cost Correlations 244
A.1. Sizing the Column 244
A.2. Capital Cost 244
A.3. Operating Cost (Op) 244
A.4. Total Annual Cost (TAC) 245
A.5. References 245
Appendix B. Response Surface Methodology 246
B.1. Introduction to Response Surface Methodology 246
B.2. Linear Regression and Least Square Method 246
B.3. Location of the Stationary Point 249
B.4. The Box – Behnken Design 250
B.5. References 251
Appendix C. Factorial Design 252
C.1. Introduction to Factorial Design 252
C.2. The 22 Design 253
C.3. References 254
Curriculum Vitae 255
Abstract in Korean 268

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