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FLNG
Performance
Feature
Optimization
HSE
32
controlled by means of flooded condenser by varying the top product flow and hence the surface area
of condenser.
Project Objective
The main objective of the simulation modelling
was to find out the energy reduction potential in the
VCM column without any capital investment.
Methodology
The methodology followed in this study is outlined below.
1. Selection of model from Aspen Plus for distillation column
2. Selection of property method
3. Validation of property method based on process
flow diagram (PFD)
4. Preparation of distillation column model
5. Validation of the model based on Licensors PFD
6. Fine tuning of the model based on present
operating parameters
7. Sensitivity analysis
8. Trial plan based on optimized window
9. Analysis
10. Conclusion
Aspen Plus simulation software is used for steady
state simulation. For the purpose of optimisation
study, Radfrac, a rigorous model for distillation
columns, was selected.
Peng Robinson was selected as a property method
and it was validated based on property data prediction by the method and by comparing the same with
the actual flow diagram provided by the Licensor.
The flowsheet was prepared in the Aspen Plus
simulation environment resembling the actual flow
scheme of the column.
Initially, the PFD data was taken for feed composition and the prediction of the model for the top
and bottom products was compared to the component-wise composition in material balance table on
the PFD. Next actual feed compositions were analysed and input to the model and the model predictions carefully evaluated. Fine tuning of model was
done through Murphree tray efficiency adjustments
and following parameters were matched with actual plant data.
Temperature profile along the column
Condenser and reboiler duty
Reflux and steam flow
Top and bottom products composition
Case study and sensitivity analyses were then
performed to understand the effect of various variables like column pressure, reflux ratio, etc., without compromising the top and bottom product
specifications.
It was concluded from the simulation study that
it is possible to reduce the reflux ratio from operating value of 0.42 to 0.38 without compromising
product quality. This recommendation was implemented by a step-wise reduction of the reflux
ratio in operating plant.
Beyond energy savings, the same simulation
model was utilized for evaluating the potential for
increased throughput in the column. The tray ratings were done by specifying the existing geometry of sieve trays, and the flooding tendency was
evaluated in various sections of the column. Simulation results showed that the column can be operated at 120% of normal operating throughput and
the same was implemented in the plant.
The results from both the energy / reflux analysis
and the increased throughput analysis are summarized in the table below.
Feed flow
m3/hr
Normal Operation
53.84
After simulation implementation
54.11
Higher capacity operation (120% of normal) 64.50
Figure 2. VCM Column Simulation Study Results
Reflux flow
m3/hr
10.64
9.60
10.50
The simulation model prediction was highly accurate and very close to reality. The same column was
operated at 120% of normal operating throughput
as predicted from the results of simulation which
yielded additional capacity of 10.3 tonne/hr of feed.
HA
Enquiry Number
10/12-07
Steam flow
kg/hr
5270.55
4901.68
5607.00
Top pressure
kg/cm2g
6.00
6.00
6.00
References
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