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, (199 1) 97-108
Abstract
final form January 29, 1991)
A simple equation is presented which estimates the cost of one sequence relative to that of
another and which identifies the o p t i sequence for examples which have been solved
previously in the literature using other methods. The equation uses only the mole fractions of
the components in the feed and the volatility of one component relative to another. The proposed
equation may be used to list all the possible sequences in order of cost and this order is the
same that obtained by the more exact methods. Above all, it provides a quantitative expression
of the most powerful heuristics. The equation is straightforward, and quickly evaluated by hand.
It thus provides a more reliable method of identifying the optimum sequence than the method
based on the use of heuristics.
The equation is less accurate where the relative volatility of two of the components in the
mixture is very small (less than 1.1) but for this case the cost is usually dominated by the
difficult separation (small cost differences between alternative sequences) and the sequence
identified by the equation is likely to be that most suitable for energy integration.
1
splits, (3) emove the most plentiful component
iirst, and (4) remove the lightest component
(i.e. favo the so-called direct sequence).
There are many more heuristics and more
than 22 have been found in the literature [8,
bore Malone et al. [25] derived a
appromation for the overhead vapour
=ate for a ternaw mixture which was shown
compare well with that calculated by the
U~denvoodequation. This was used to derive
101. Sometimes the rules of thumb contradict aQ equation for choosing the optimum se-
each other. For example, the heuristic "do the qbence, which again was assumed t~ be that
easiest separation first" is often contradicted With the smallest overhead vapour flow. EX-
by the heuristic "favour the direct sequence", this procedure to more than three
thus there are one or two papers published
which describe "rules of thumb" for using the
EQmponents may result in an expression which
becomes undesirably complicated" [26].
heuristics (3, 151. Also of ifiterest are refs. 27 and 28 in which
The alternative approach is optimization us- the authors a,nalysed eight distillation se-
ing either evolutionary or algorithmic tech- 9bemes (including complex columns and side
niques. These are usually very rigorous but separating ideally behaving three-
require mathematical skills from the user. Ref- Component mixtures of hydrocarbons. They
erences 15-18 are important works on the ' h a r i z e d their results on triangular dia-
evolutionary technique.
gpams.
i cred- We do not consider complex distillation col- For the examples cited, the relative volatility
uses umns in this paper. Only conventional columns cu,, is either taken from the references quoted,
timum without energy integration are considered. where available, or calculated at the feed con-
other However, unlike the previous work mentioned ditions.
above, the equations presented (eqns. (la) and In the derivation of the ROTE equation, it
n pro- (lc)) may be used with any number of com- is to be noted that the assumption of sharp
3rches ponents. separations implies that on the basis of one
e and mole of feed, mole fractions in the feed are
'ecom- equivalent to the molar flows of those com-
calcu. 2. Derivation of the ROTE equation
ponents entering or leaving a column in the
lences sequence.
e heu- This is based on simplification of the problem +
Consider the separation of A + B . . . + LK
resent listed below. It should be noted that because
our objective is only to put all the possible
+ + + + +
from the mixture of A B . . . LK HK
tre the
sequences in order of their relative cost, a
. . . + m in a column j. Assume that there are
to use no (HK+ . . . + m) at the top, i.e. xHK and other
tradict greater degree of simplification is permissible heavier components are zero. Then from eqn.
re are than if our objective were to approximate to
the actual cost of each sequence. (2)
math-
com- (1) Capital cost implications are ignored the
analysis is based on energy cost only. This
rive a assumes either that a distillation is dominated
:s, i.e. by energy costs, or that there is a constant +
But Vj= (1 R)W (4)
3 . This ratio between the energy cost contribution to
the total cost and that of the capital cost (see where W is the moles of distillate from the
ernary column joules per mole of feed to the whole
discussion of Fig. B3 below).
(2) The total energy costs are assumed to sequence.
wo al- For R =RfRm,, eqn. (4) becomes
Uation be proportional to the total overhead vapour
- flow, load. Thus the most economical sequence will
l e op- be that with the minimum total flow. (This
t over- assumption has been used in previous work
;ion is [24, 251.) Simplifications (1) and (2) are dis-
1 does cussed in Appendix B.
ill the (3) Sharp separations are assumed through-
multi- out the sequence. That is, the distillate contains
:m as only the light key and lighter components and
the bottom product contains only the heavy
ived a key and heavier components. Now
(4) It is assumed that the minimum reflux
ratio R, for any column can be calculated
by the by the simple method for a binary mixture and
derive applied to the key components. That is, for
Lm se- key components LK and HK
)e that
N . EX-
three
which where subscripts D and F refer to distillate
161. and feed.
wluch This simplification is the most difficult to
In se- just* and is discussed further below. The
~dside actual reflux ratio R is then calculated by
three- multiplying the minimum reflux ratio by a This is the equation which links relative volatilities
, They constant ratio of 1.1, or by a ratio which varies and concentrations. For the whole sequence, the
tr dia- to take into account materials of construction, BDTVL is given by the ROTE equation (eqn.
cost of energy, operating pressure etc. (1~)).
3. Discussion table shows that the ROTE equation vapour
load values appear in the same order. Also
Equations (la) and (lc) provide a quanti- shown is total annual cost calculated by our
tative expression of the most powerful own cost-estimating computer program with
heuristics. Thus the heuristic "favour the direct the cost factors taken from Happel and Jordan
sequence" produces a mbhnum value for the [30]. The minimum number of plates N,, g
sum of the &st (distillate) terms, while the obtained from the Fenske equation 1311, and
heuristics "do the easiest separation first" and the minimum reflux ratio R,, from the Un-
"do the most difficult separation last" comply derwood equation 1291. The Erbar-Maddox
with a minimum value for the sum of the equation 1321 is then used to calculate the
...F'v- -
I : I minimum vdue for the sum of the second more rigorous plate-to-plate method 1331 to !i
obtain the heat loads. For more details, see
i
(feed) terms.
Tn T a h l ~1 W P liqt t h e BDTVL calculated by Appendix C or ref. 10. The column pressure
.f +&- " 8 possible se- is set by the water cooling condenser tern-
to perature. The order of the sequence given by
; / I
1
//
TABLE 1
List of ROTE vapour load and the total annual cost TAC
for the three lowest cost sequences are shown.
These are put in the order calculated in the
references ~h~ ROTE equation (eqn.
in U.S.$
(1)) has identified the lowest cost sequence
i!
/
1
//
1
1
Mlxture 1, SIX-componentmucture 141
1
!I
1 I
c
D
E
nee-pentane
n-pentane
n-hexane
0.10
0.15
0.25
".+"
2.2308
2.9678
2.8736
prising in view of the simplifications used in
the derivation of eqns. (la)-(lc), particularly
the assumption that the minimum reflux ratio
may be calculated as for a binary mixture in
The feed is saturated liquid in an columns (453.6 kmol h-I) terms of the relative volatility of the key corn-
ponents only. It is known that the presence
Sequence in the Vapour flow per Total annual cost of other components and their volatilities in-
order of TACa mole of feed by by design and fluences the se~aration,and that more com-
the ROTE costing methods plicated methods are required to calculate the
equation
Of 1101 ($) minimum reflux ratio, such as the shortcut
1 3.0595 2 746 441
method of Underwood [29] or a numerical
2 3.0901 2 821 804 calculation for each column.
It is then of interest to consider why the
4 3.3031 2 831 493 method based on eqns. (la)-(lc) succeeds in
5 3.3287 2 856 575 listing the possible sequences in order of cost.
6 3.3431 2 905 981
Figure 2 shows sequences presented in their
7 3.3914 2 915 669
8 3.4092 2 920 143 order of relative cost by Stephanopoulos et
9 3.4349 2 940 751 aL. [4]. The comparison shows that the ROTE
10 3.4493 2 953 942 method is a sensitive way of distinguishing
11 3.4976 2 995 507 between sequences and that this method of
12 3.5153 3 012 023 comparison becomes more accurate as the
13 3.6220 3 029 305
optimum minimum cost sequence is ap-
T h e order of cost as taken from the reference. proached. This is because as the optimum
101
A
per mole of
feed by the
ROTE
equation
- --
Total annual
cost by design
and costing
methods of
Momoh [lo]
fraction volatility
311, and ($1
the Un- A propane 0.05 2.00
-Maddox B i-butane 0.15 . 1.33 Mixture 4a
date the C n-butane 0.25 2.40 0.37, 0.37 1 1.7571 1 659 263
0.20 0.26 2 2.2251 1815 548
1ming R / D i-pentane 1.25
(270 limo1 h-')
lint for a E n-pentane 0.35
Mixture 4b
1331 to The feed is saturated liquid in alI columns (907.2 kmol h-I). 0.33, 0.33, 1 1.7043 1 854 914
;ails, see 0.34 2 2.0580 1 923 381
pressure (300 kmol h-')
ser tem- Sequence in the Vapour flow per Total annual cost
Mlxture 4c
given by order of TAGa mole of feed by by design and
0.11, 0.11 1 1.1387 4 242 720
the ROTE costing methods
n vapour 0.78 2 1.4137 5 544 617
equation of Momoh [ l o ] ($)
10s et al. (900 kmol h-')
1 5.8257 8 342 116 Mixture 4d
her pub- 2 5.8840 8 490 177 0.083, 0.083, 1 1.0258 5 526 720
le results 3 6.3998 9 075 389 0.834 2 1.3780 7 472 997
.e shown. (1200 kmol h-')
T h e order of costs as given by the authors.
3d in the T h e order of cost as given by the authors.
.on (eqn.
sequence 1 Mixture 3, five-component mulure {4]
T
5 A. Elaahi and W. L. Luyben, Ind. Eng. C
Number Number of cases where the Des. Dm., 22 (1983) 80.
sequence of cases optimum sequence(s) as predicted 6 J. E. Hendry, D. F. Rudd and J. D. Sea er, AIChE
1 27 out by ROTE agree with TAC J., I 9 (1973) 1.
was that 7 V. Hlavacek, Comput. Chem. Eng., 2 (1 78) 67.
:st ROTE Best Best or second 8 N. Nishida, G. Stephanopoulos and A. W. Westcrberg,
sequence best sequence AIChE J., 27 (1981) 321.
20 10 12 9 A. W. Westerberg, Cornput. Chem. Eng., 9 (5) (1985)
.ence be- 421.
of C O ~ - 1 1 0 S. 0. Momoh, Ph.D. Thesis, Aston University, Bir-
ities, the For these cases, the sequence with the small- mingharn, 1986.
cost se- 11 F. J. Lockhart, Pet. Refiner, 26 (1947) 104.
est value of ROTE vapour load was always 1 2 V. D. Harbert, Pet. Refiner, 36 (1957) 169.
valuated. that which made the difficult separation the 13 G . J. Powers, Chem. Eng. Prog., 68 (8) (1972) 88.
>rthe 20 last column in the sequence, i.e. the difficult 1 4 H. Nishimura and Y. Hiraizumi, Int. Chem. Eng., I 1
paration, separation became a binary separation with a (1971) 188.
? COSt of 1 5 J. D. Seader and A. W. Westerberg, AIChE J., 23
small temperature change over the column.
3ther for This implies that the sequence with the lowest (1977) 951.
16 G. Stephanopoulos and A. W. Westerberg, Chem. Eng.
ROTE vapour load is likely to be that most Sci., 31 (1976) 195.
17 C. J. King, D. W. Gantz and F. J. Barnes, Ind. Eng. heat transfer area of the condenser
Process Des. Dm., 11 (1972) 272.
18 R. Nath and R. L. Motard, AIChE J., 27 (1981) 578. (m2>
19 J. E. Hendry and R. R. Hughes, Chem. Eng. Prog., AP cross-sectional area of the column
68 (1982) 69. (m2>
20 A. W. Westerberg and G. Stephanopoulos, Chem. E q . AR heat transfer area of the reboiler (m2)
Sci., 30 (1975) 963. cc cost of condenser
21 F. R. Rodrigo and J. D. Seader, AlChE J., 21 (1975) specific heat capacity of water, 4.1868
885. CPw
22 M. A. Gomez and J. D. Seader, AIChE J., 22 (1976) kJ kg-' K-l
970. cost of reboilei ($)
23 A. Gomez-Munoz and J. D. Seader, Comput. Chem. cost of reboiler heating steam ($)
Eng., 9 (4) (1985) 311. cost of condenser cooling water ($)
24 V. Rod and J. Marek, Coll. Czech. Chem. Commun., cost of column ($)
24 (1959) 3240.
25 M. F. Malone, K. Glinos, F. G. Marquuez and J. M. unit cost of cooling water ($0.023
Douglas, AIChE J., 31 (1985) 683. per m3) and unit steam cost ($0.02
26 K. Glinos, M. F. Malone and J. M. Douglas, AIChE per kg) respectively
J., 31 (1985) 1039. distillate rate (per mole of feed to the
27 D. W. Tedder and D. F. Rudd, AIChE J., 24 (1978)
sequence)
303.
28 D. W. Tedder and D. F. Rudd, AIChE J., 24 (1978) overall frictional column efficiency
316. feed rate (kmol h-I)
29 A. J. V. Underwood, Chem. Eng. Prog., 44 (1948) number of hours of operation per year
603. indices identifying components in a
30 J. Happel and D. G. Jordan, Chemical Process Eco- multicomponent mixture
nomics, Marcel Dekker, New York, 1975, 2nd edn
31 M. R, Fenske, Ind. Eng. Chem., 24 (1932) 482. index for any column in a sequence
32 J. H. Erbar and R. N. Maddox, Latest score; reflux of columns
versus trays, Pet. Refiner, 40 (1961) 183. 0.3, the factor converting the capital
33 L. M. Naphthali and D. P. Sandholm, AIChE J., I7 cost of equipment to an annual cost,
(1971) 148. equivalent to a payback time of three
34 R. N. S. Rathore, K. A. Van Wormer and G. J. Powers,
AIChE J., 20 (1974) 491. years
35 N. Doukas and W. L. Luyben,Ind. Eng. Chem. Process parameter in eqn. I@); number of
Des. Dev., 17 (1978) 272. times a component appears in top
36 K. E. Porter, S. 0. Momoh and J. D. Jenkins, Inst. product stream either alone or with
Chem. Eng. Symp., Ser. 104, Institute of Chemical other components throughout the se-
Engineers, Rugby, 1987. quence as a whole
37 P. A. Mindeman and D. W. Tedder, AlChE Symp.
Ser. 78 (1982) 69.
unit cost of column or plate area ($
38 E. J. Henley and J. D. Seader, Equilibrium-Stage per m2 or plate)
Separation Operations in Chemical Engineering, cost of heat exchanger or heat transfer
Wiley, New York, 1981. area ($m2)
39 C. G. Kirkbride, Pet. R e f i w , 23 (1944) 187 (3219). heavy key component
40 J. R. Fair, Pet. Chem. Eng., 33 (1961) 45. light key component
4 1 A. Fredenslund, R. L. Jones and J. M. Praustniz, AIChE
J., 27 (1975) 1086.
light heavy keys
42 J. Gmehling, P. Rasmussen and A. Fredenslund, Ind. mth components in a mixture of m
Eng. Chem. Process Des. Dm., 21 (1982) 118. components
43 & Fredenslund, J. Gmehling and P. Rasmussen, Va- number of components
pour Liquid Equilibria using VNIFAC - a group number of columns
contribution method, Elsevier, Amsterdam, 1977. number of plates
44 R. C. Reid, J. M. Prausnitz and T. K. Sherwood, The minimum number of plates
Froperties of Gases and Liquids,McGraw-HiU, New
York, 1977, 3rd edn.
condenser heat load (kJ h-I)
45 A. V. Bridgwater, Process Econ. Int., 4 (2) (1983) reboiler heat load (kJ h-I)
26. unity if component i exists in the
stream entering column j,zero other-
wise
Appendix A: Nomenclature R external reflux ratio
Rf R IRmin
A, B components in a multicomponent R,,, minimum reflux ratio
mixture At temperature rise in cooling water 0
I 105
:I 1 AT,,
ATh,.
., logarithmic mean temperature driving
force in condenser and reboiler re-
p, density of water (1000 kg m-3)