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ANDREW W. SLOLEY,
THE DISTILLATION GROUP, INC.
eCopyright 2000
American Institute
of Chemical Engineers.
All rights reserved.
Copying and
downloading permitted
with rctrs..
Distillation
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Jariury 2001
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39
DistilLation
Figure 1. Net vapor rate> 0, direct control of product rate.
1
----c-Table 1. Common methods for pressure
control of towers.
-
Type
Method
(Figure No.)
1A
1
Description
Net vapor rate always zero
Direct control of vapor product rate
1A
1A
1A
1A
1A
2A+
2A
3B
10
3B
11
38
12
38
condenser at low
condenser at high
Warnings:
13
3B
14
3D
15
3D
16
3E
17
3E
18
3E
19
3C
>
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>
Advantages: All ejector discharge available for recycle, often gives the
most stable operation.
Warnings:
(5); these are unusual, however, and will not be covered here.
Most of the control systems detailed are in cunent use in
refineries and petrochemical plants. Other industries may have
specific control options available that are not covered here.
Process considerations
The two major earlier reviews of pressure control took
different approaches to categorizing the methods. Boyd (3)
broke down the control systems into groups based on distilla
>
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January 2001
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Distillation
>
>
-Steam
Vapor Product
(To Additional
Vacuum Producers)
Vapor Product
Water
Not Recommended
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Warnings:
Point
Method: Various.
Process: Net vapor rate positive or zero.
Advantages:
Disadvantages:
Application: Effective choice for systems that require inert venting.
Variants: Many.
Configuration notes: Can be used with methods that allow for variable con
denser duty. See Figures 911 and 1319 for examples. The flooded drum
(Figure 12) is not suitable for addition to this basic method.
Operation: Direct control of overhead pressure. Differential pressure (DP)
is manipulated to control condensation temperature in condenser
this
varies the condensers log-mean temperature difference (LMTD). When
pressure rises above the high set point on the receiver, the high-set-point
controller opens and gas leaves the system.
Warnings:
Warnings:
Recommendations
Many factors specific to the particular column must be
considered in deciding which control method to use. As a
starting pomt, however, consider the following suggestions
for common situations:
Vet iapor a/ams > 0 or vapor product on/i Method I
usually is the simplest and best.
Vapor product to compression ststem. Method 2 is recom
mended for such situations.
Steam jet ejector sis!ems. Method 3 is suggested for sys
tems with precondensers or with the vacuum system taking
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Distillation
pressure.
Variants:
Configuration notes: Pressure in the drum and column overhead are the
same. Equalizing line is needed for stable control. Liquid from condenser
must enter the drum in the liquid layer so tnat control valve changes can
affect liquid level in the condenser. Preferred application is liquid entry
into drum from below (shown). If air-fins are used for the condenser, they
should be angled to allow for gradual surface-area changes with liquid
level changes. Cooling is done at the lowest possible utility temperature
(potential problem for cooling water, potential advantage for heat-integrat
ed cryogenic systems).
Operation: Control valve imposes a variable DP in main flow line through
condenser. Liquid level in control line up to exchanger varies with DP
ting area from condensa
6
changes. This exposes or submerges tubes, shi
tion to subcooling.
Warnings:
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To sum up
Effective pressure control improves distillation operations.
Many control configurations arc possible. Choice depends
upon process and coolingutility condilions. equipment con
figuration. and operating objectives. This article has pieseit
ed a variety of prvssure control methods, as well as a general
system of classification for them, It also has provided a guide
to selection according to these classifications, and some gen
eral t-ecommendations.
Of course, the choice of a control method for a specific
Disadvantages: Concept is not straightforward. and method requires subcooling area in condenser.
Application: Often used with very large and heavy condensers or with
equipment requiring recurring cleaning or maintenance (exchangers at
grade).
Variants: Condensate drum pressure instead of tower overhead pressure
may be controlled. Works for units with continuous vapor products as well.
In this case, vapor product composition is tower overhead composition
and the condenser does not count as a separation stage.
Configuration notes: General method often is referred to as hot vapor by
pass. A liquid level must be maintained in e exchanger at all times.
Careful attention to piping is required. Liquid must enter the drum without
mixing with the drums vapor space (7J This mandates either having the
liquid enter the drum from tne bottom or having an internal pipe down from
the top. The author prefers bottom entry as it creates less liquid turbu
lence. The control valve and bypass tine must be sized so that the bypass
flow-rate changes allow for a DP change that corresponds to the liquid
level range available in the conde-iser
Operation: To maintain pressure, the control valve DP is manipulated. As
the control valve DP changes. the pressure balance between the bypass
and the condenser flows varies the liquid level in the condenser. This
changes the allocation of condensing vs. suhcooiing surface available. Tie
liquid and vapor are not in equilibrium. A tf in layer of hot liquid separates
the bulk liquid pool from the vapor. This essentially allows for mainta:crg
drum pressure with a blanketing layer of tower overhead vapor instead of
externally supplied vapor.
Warnings: Some units have worked very well with this scheme, but others
have failed. Selection of bypass rates and exchanger surface required is
mostly empirical Some general problem areas for this method are:
High purity products: This method does not work well with high pu
rity products that have narrow boiling ranges. The liquid insulating layer
between the bulk condensate pool and the vapor space fails to adequately
insulate the liquid. Control is erratic.
Seif-refluxing condensers: Heavy material in Ire overnead vapor
condenses first. Some liquid falls to the bottom of the exchanger and runs
along it to the outlet. This may change the composition of the vapor
enough that, at the outlet of the condenser, the vapor is no longer fully
condensable.
Corrosion of internal pipe: If a top entrance of liquid into the drum
is used, the internal pipe must not corrode through. A hole corroded in the
internal pipe above the liquid level can lead to mixing of the topmost not
liquid layer and, thus, to unstable operation. Keep in mind that tne internal
pipe may corrode from both sides.
Conlinuts
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45
Distillation
Figure 13. Net vapor rate
condensate.
Makeup
Variants:
Configuration notes: A liquid level must be maintained in the exchanger
at all times.
Operation: Variable product rate changes the level in the condenser.
Warnings:
Warnings:
Advantages:
Disadvantages: Difficult to add blowdown on vaporizing coolant.
Application: Used with heat recovery by having condenser rehoil another
Warnings:
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Warnings:
Variants:
Configuration notes: Cooling water fouls more rapidly with increasing tem
(ontinifts OflJ).
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48
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DistilLation
NC
Warnings:
Literature Cited
I. Linslcv. J.. New. Simpler Equations Calculate Pressure-Compensat
edTemperatures, Oil& GasJ., 95(12), pp.58-64 (Mar. 24, 1997).
2. Fleming, B.. and A. 4. Sloler, Feeding and Drawing Products.
The Forgotten Part of Distillation, presented at (hemShow and Ex
position, New York (Dec. 1995).
3. Boyd, D. M., Fractionator Pressure Control, Pet,: Ref. 26 (2),
pp. l131l5 (Feb. 1947).
4. Chin. T. G., Guide to Dtstillatton Pressure Control Methods. Hv
droc. Proc., 86(10). pp. 145-153 (Oct. 1979).
5. Kister. I-I. Z., Distillation Operation. McGraw-Htll, New York
(1989).
6. Slolev, A. W., Steady Under Pressure. lresented at AIChE Nation
al Meeting. Atlanta (Mar. 2000), available on-line at http://www.dis
tillationgroup.comitechntcali08 I html.
7. Slole, A. W., Simple Methods Solve Exchanger Problems. Oil
and Gas J., 96(lf,).pp. 58 59(Apr.20 1998).
8. Bod, D. M., Fractionator Instrumentation and Control Part 1,
Pet,: Ref. 27(1(1). pp 115-118 (Oct. 1948).
9. Hollander, L., Pressure Control of Light-Ends Fractionators. 1S.4
1. 4(5), pp. 185-187 (May 1957).
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Variants:
Configuration notes: Cooling is done at lowest possible utility tempera
ture (9) (potential problem for cooling water, potential advantage for heat
Further Reading
Lieberman, N., Instrumenting a Plant to Run Smoothly, Chem. Eng..
84 (19). pp. 140 154 (Sept. 12. 1977).
Rademaker, 0., J. E. Rijnsdorp, and A. laarleneld. Dynamics and
Control ofContinuous Distillation Units, Elsevier. Amsterdam (1975).
Riggs, J. B., Improve Distillation Column Control. C/tern. Eng.
Progress. 94 (10), pp. 3147 (Oct. 1998).
Whistler, A. M., Locate Condensers at Ground Level, Pet,: Ref. 33
(3),pp. 173 174 (Mar. 1054).