New Approach for Modeling Hybrid Pressure Swing Adsorption-Distillation Processes Fan Wu University of South Carolina

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New Approach for Modeling Hybrid Pressure Swing Adsorption-Distillation Processes Fan Wu University of South Carolina University of South Carolina Scholar Commons Theses and Dissertations 1-1-2013 New Approach for Modeling Hybrid Pressure Swing Adsorption-Distillation Processes Fan Wu University of South Carolina Follow this and additional works at: https://scholarcommons.sc.edu/etd Part of the Chemical Engineering Commons Recommended Citation Wu, F.(2013). New Approach for Modeling Hybrid Pressure Swing Adsorption-Distillation Processes. (Doctoral dissertation). Retrieved from https://scholarcommons.sc.edu/etd/2374 This Open Access Dissertation is brought to you by Scholar Commons. It has been accepted for inclusion in Theses and Dissertations by an authorized administrator of Scholar Commons. For more information, please contact [email protected]. NEW APPROACH FOR MODELING HYBRID PRESSURE SWING ADSORPTION-DISTILLATION PROCESSES by Fan Wu Bachelor of Science Dalian University of Technology, 2008 ––––––––––––––––––––––––––––––––––––––––––––––––––– Submitted in Partial Fulfillment of the Requirements For the Degree of Doctor of Philosophy in Chemical Engineering College of Engineering and Computing University of South Carolina 2013 Accepted by: James Ritter, Major Professor Armin Ebner, Committee Member Edward Gatzke, Committee Member John Weidner, Committee Member Jamil Khan, Committee Member Lacy Ford, Vice Provost and Dean of Graduate Studies © Copyright by Fan Wu, 2013 All Rights Reserved. ii DEDICATION To Xueqiang Wu and Yan Dong, my parents for their love and support. iii ACKNOWLEDGEMENTS I would like to express my deepest appreciation to my advisors Dr. Ritter and Dr. Ebner who has given me the opportunity to join their group and to do this wonderful project, also for the knowledge, technology and everything they have taught me and for their patient guidance and mentorship throughout the completion of this degree at University of South Carolina. I would also like to thank my committee members, Dr. Edward Gatzke, Dr. John Weidner and Dr. Jamil Khan for taking time from their busy schedule to be my committee members and every piece of advice they have given to me during this PhD program including the comprehensive exam, pre-defense exam and final defense exam. I would like to express my appreciation to Dr. Marjorie Nicholson for her help in the lab and being so nice to me, also Charles Holland for his genius in building experiment systems. I want to acknowledge all present and prior classmates in the research group, Dr. Jan Mangual, Dr. Hai Du, Dr. Amal Mehrotra, Dr. Shubhra Bhadra, Dongxiang Yang, Mohammad Iftekhar Hossain, Anahita Abdollahi, Lutfi Erden, Hanife Erden, Atikur Rahman and Nima Mohammadi for their support and inspiration. In addition, I would like to appreciate all my friends who have made my life at University of South Carolina filled with happiness. A special thanks goes to my cat iv Sesame who has been an alarm clock to wake me up early in the morning and messed up my bedroom with his claws. Especially, I want to thank my parents, Xueqiang Wu and Yan Dong, for their love and support during my five-year studying aboard. I want to apologize to them for being so away from them for so many years and for not carrying out the obligation as a daughter of them. Finally, I want to appreciate the funding provided by ExxonMobil and Process Science and Technology Center who has made this dissertation possible. v ABSTRACT A new methodology for modeling hybrid pressure swing adsorption (PSA)-distillation processes has been developed. Two hybrid systems were simulated as examples. One is for ethanol dehydration, and the other is for propane/propylene separation. Firstly, a distillation process simulator such as Chemsep was used to simulate the distillation process of the hybrid system, in which the PSA unit was treated as a “black box” with an assumed process performance. In this way, a hybrid PSA-distillation process can be analyzed simply by performing mass balances around these units and running Chemsep to determine the possibility of energy saving compared to a reference (commercial) process. Once an energy saving hybrid “black box” PSA-distillation process was found, a rigorous PSA process simulator was used to simulate a “actual” PSA process by designing the operating conditions, cycle scheduling, etc. Then the distillation process was simulated again with the “actual” PSA performance to calculate the distillation operating cost, followed by calculating the total operating cost of the whole hybrid process. According to the results in this dissertation, significant cost saving could be achieved compared with the traditional processes. The commercial hybrid PSA-distillation uses a simple 2-bed 4-step PSA cycle. It vi is surmised that the PSA performance can be improved by designing a more complicated PSA cycle with more beds and steps. In this work, four different PSA cycles were designed and simulated using the dynamic adsorption process simulator (DAPS). The performances of these cycles were put back into the hybrid system to calculate all the costs and compare the results with the 2-bed 4-step commercial hybrid PSA-distillation process. The total operating could be reduced significantly and the distillation capacity could also be increased. For propane/propylene separation, more energy efficient configurations were designed to compete with the traditional simple distillation process which is a large energy consumer. A hypothetical adsorbent was conceived that has all the desirable and none of the undesirable properties of the commercial adsorbents already tested for this separation. Several PSA cycles configurations that utilize this hypothetical adsorbent under different operating conditions have been investigated via simulation. The results show that a hybrid PSA-distillation process is able to achieve significant energy saving compared to the traditional distillation process. vii TABLE OF CONTENTS DEDICATION ....................................................................................................................... iii ACKNOWLEDGEMENTS ...................................................................................................... iv ABSTRACT .......................................................................................................................... vi LIST OF TABLES .................................................................................................................. x LIST OF FIGURES ............................................................................................................... xii LIST OF SYMBOLS ........................................................................................................... xvii LIST OF ABBREVIATIONS ............................................................................................... xxiii CHAPTER 1: METHODOLOGY FOR MODELING HYBRID PSA-DISTILLATION PROCESSES WITH ETHANOL DEHYDRATION AS AN EXAMPLE ............................................................... 1 1.1 Summary ................................................................................................................ 1 1.2 Introduction ............................................................................................................ 2 1.3 Hybrid Process Concept ......................................................................................... 4 1.4 Hybrid PSA-Distillation Process Configurations .................................................. 6 1.5 Reference and New Hybrid PSA-Distillation Process Flow Sheets .................... 10 1.6 Simulation Approaches ........................................................................................ 12 1.7 Results and Discussion ........................................................................................ 22 1.8 Conclusions .......................................................................................................... 39 CHAPTER 2: IMPROVED PSA CYCLES OF HYBRID PRESSURE SWING ADSORPTION-DISTILLATION PROCESS FOR ETHANOL DEHYDRATION ............................ 49 2.1 Summary .............................................................................................................. 49 2.2 Introduction .......................................................................................................... 49 2.3 Modeling .............................................................................................................. 51 2.4 Results and Discussion ........................................................................................ 61 2.5 Conclusions .......................................................................................................... 67 viii CHAPTER 3: SINGLE PSA SYSTEM AND DUAL TRAIN PSA SYSTEM FOR ETHANOL DEHYDRATION .......................................................................................... 76 3.1 Summary .............................................................................................................. 76 3.2 Introduction .......................................................................................................... 77 3.3 Single PSA System Simulation ............................................................................ 79 3.4 Dual Train PSA System Simulation .................................................................... 88 3.5 Conclusions .......................................................................................................... 95 CHAPTER 4: MODELING OF HYBRID PRESSURE SWING ADSORPTION-DISTILLATION PROCESS FOR PROPANE/PROPYLENE SEPARATION .......................................................
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