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1 Eldridge Research Group Melissa Donahue Bailee Roach Jeff Weinfeld Colton Andrews Johannes Voggerneiter 1
2 Modeling of Multiphase Contactors with Computational Fluid Dynamics
3 Dividing Wall Distillation 3
4 Control of a Dividing Wall Distillation Column Melissa Donahue, Bailee Roach, Michael Baldea, and R. Bruce Eldridge October 18 th,
5 Agenda DWC Overview Pilot Plant Results Feed System #1 Feed System #2 Future Work 2
6 Motivation Dividing Wall Column (DWC) Benefits: Reduce reboiler duty Lower environmental impact Minimize irreversible mixing Reduce capital investment Assumptions: Ideal vapor Ideal liquid No pressure losses No wall heat transfer Constant relative volatilities % of Traditional Reboiler Duty 50% α a = 1.21 α b = 1.10 α c = 1.00 A:30 B:40 C:30 Source: R. Agrawal R and ZT Fidkowski 80% 90% 60% 70% 60% 70% 80% 90% 3
7 Traditional Distillation A B A B C B C C 4
8 DWC Operation A A B C B C 5
9 DWC Operation A A A B A B C B A B C B B B C [1] I. J. Halvorsen and S. Skogestad, Optimal Operation of Petlyuk Distillation: Steady-State Behavior, Journal Of Process Control, no. 9, pp , C C 6
10 DWC Pilot Plant Rectifying Section Upper DW Section Lower DW Section Stripping Section 7
11 Process Flow Diagram Top Product Top of Wall Tank Feed Heater Side Product Product & Feed Tanks Steam 8
12 Feed System #1 DB/LSV Chemical α ic α ij A 6.66 B 1.66 C D Distillate Flow B Bottoms Flow L Reflux S Side Draw Flow V Vapor Boilup Ling, H.; Luyben, W. Temperature Control of the BTX Divided-Wall Column. Industrial and Engineering Chemistry Research 2010, 49,
13 Temperature ( F) Feed System # :57:36 PM 7:55:12 PM 8:52:48 PM 9:50:24 PM Time Top Temp SP Top Temp PV Upper Prefrac Temp SP Upper Prefrac Temp PV Lower Mainfrac Temp SP Lower Mainfrac PV 10
14 Temperature ( F) Feed System # Location Purity (mole % A/B/C) Bottoms Product 0/8/92 Side Product 12/81/7 Top of Wall 83/16/1 Distillate Product 100/0/ :43:12 PM 7:40:48 PM 8:38:24 PM 9:36:00 PM Time Top Temp SP Upper Prefrac Temp SP Lower Mainfrac Temp SP Top Temp PV Upper Prefrac Temp PV Lower Mainfrac PV 11
15 Temperature ( F) Steam Flow (lb/hr) Feed System # Steam Flow :04:48 PM 4:26:24 PM 4:48:00 PM 5:09:36 PM 5:31:12 PM Time -10 Top Temp SP Top Temp PV Mainfrac Temp SP Mainfrac Temp PV Stripping Temp SP Stripping Temp PV Steam 12
16 Model Predictive Control Control Variables Top Temp Prefrac Temp Mainfrac Temp Bottom Temp Manipulated Variables Reflux Wall Split Side Draw Ratio Steam Flow FY o MPC run through DeltaV PredictPro o Model identified using pseudorandom binary sequence testing process o Four hour testing time FY 13
17 Temperature ( F) Feed System # Temperature Control using MPC Rectifying Temp SP Rectifying Temp PV Prefrac Temp SP Prefrac Temp PV Mainfrac temp SP Mainfrac Temp PV :57:36 PM 10:33:36 PM 2:09:36 AM 5:45:36 AM Time 14
18 mole frac mole frac mole frac mole frac Feed System #1 Top Product Top of Wall n-pentane cyclohexane n-heptane n-pentane cyclohexane n-heptane :57:36 PM 10:33:36 PM 2:09:36 AM 5:45:36 AM :57:36 PM 10:33:36 PM 2:09:36 AM 5:45:36 AM Time 0.7 6:57:36 PM 10:33:36 PM 2:09:36 AM 5:45:36 AM :57:36 PM 10:33:36 PM 2:09:36 AM 5:45:36 AM Time 15
19 mole frac mole frac mole frac mole frac Feed System #1 Side Product n-pentane cyclohexane n-heptane :57:36 PM 10:33:36 PM 2:09:36 AM 5:45:36 AM :57:36 PM 10:33:36 PM 2:09:36 AM 5:45:36 AM Time Bottom Product n-pentane cyclohexane n-heptane :57:36 PM 10:33:36 PM 2:09:36 AM 5:45:36 AM :57:36 PM 10:33:36 PM 2:09:36 AM 5:45:36 AM Time 16
20 Feed System #2 Chemical α ic α ij A B Ratio ontroller X C X Ratio Controller FY DB/LSV DB/LV Ling, H.; Luyben, W. Temperature Control of the BTX Divided-Wall Column. Industrial and Engineering Chemistry Research 2010, 49,
21 Feed System #2 F DB/LSV B A C F DB/LV Distillate Composition 99.83/0.17/ /0.43/0.00 Side Composition 0.24/99.49/ /99.30/0.50 Bottoms Composition 0.03/0.40/ /0.30/99.70 Top of Wall Composition 46.82/53.13/ /87.5/0.06 B A C Liquid Split 50/50 26/74 (prefrac/mainfrac) Reflux Ratio Steam Flow lb/hr lb/hr Column dp 3.62 in H2O 2.41 in H2O Feed Flow 40 lb/hr 50 lb/hr 18
22 Feed Disturbance (initial vs. final) Mole Percent A B C Starting Feed Feed Transition Feed Transition
23 Feed Disturbance Initial: FY 99.6 mol % A 0.4 mol % B 0.0 mol % C Final: FY mol % A 0.54 mol % B 0.0 mol % C FY 24.1 lbm/hr 10.6 lbm/hr 30.2 lbm/hr 3.9 lbm/hr 12.4 mol % A 87.5 mol % B 0.1 mol % C FY 7.2 lbm/hr 18.9 lbm/hr 20.5 lbm/hr 23 lbm/hr 21.7 mol % A 78.2 mol % B 0.1 mol % C 50 lbm/hr 65 lbm/hr 8.8 mol % A 77.7 mol % B 13.5 mol % C 15.5 lbm/hr 38.7 lbm/hr 0.3 mol % A 99.3 mol % B 0.4 mol % C 28.2 mol % A 41.4 mol % B 30.4 mol % C 20.2 lbm/hr 27.7 lbm/hr 1.4 mol % A 98.3 mol % B 0.3 mol % C 39.3 lbm/hr 39.2 lbm/hr 0.0 mol % A 0.3 mol % B 99.7 mol % C 9.8 lbm/hr 0.0 mol % A 0.4 mol % B 99.6 mol % C 26.1 lbm/hr 20
24 Temperature ( F) Reflux (lb/hr) Feed Disturbance Rectifying temp SP Rectifying temp PV Reflux :24:00 AM 10:04:48 AM 11:45:36 AM 1:26:24 PM 3:07:12 PM Time 21
25 Results Summary Multiple Feed Systems Stable Control 4-point, 3-point, and 2-point PID MPC derived using DeltaV Disturbance Testing Decrease in Steam Feed composition & flow Liquid Split Need to determine operating range of liquid split Prefrac temperature isn t always sensitive to liquid split 22
26 Future Work Refine Model Various Feed Compositions Feed Disturbance Testing Further MPC Testing 23
27 Thank you SRP Staff Eldridge and Baldea Groups James R. Fair Process Science Technology Center 24
28 Questions? 25
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