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Iv the Thesis Work Is Dedicated to My Beloved Parents Whose Support and Prayers Make Possible This Achievement II © Farrukh Ilyas Abid 2015 iii The thesis work is dedicated to my beloved parents whose support and prayers make possible this achievement. iv ACKNOWLEDGMENTS “In the name of Allah, The Most Merciful and The Most Gracious” All praise and thanks to Almighty, the Creator of all worlds for giving me the courage to accomplish this work sincerely and successfully. May there be every peace and blessings upon the holy prophet Muhammad (SAW), his family and his companions. Words cannot do justice to the gratitude I owe to my mentor and teacher, Dr. Abdallah Al- Shammari. He was the one who believed in me when I did not believe in myself. It was not only his academic acumen and intellect from which I benefited, but his humane, compassionate and fatherly nature which kept me going. I cherish his friendship, companionship and his astute world views more than his sharp engineering instincts. I would also like to express my sincere gratitude to my thesis Co-advisor Dr. Housam Binous for his guidance and assistance. I will also acknowledge the sincere efforts of all committee members Dr. Mohammed Ba-Shammakh, Dr. Abdulhadi Al-Juhani and Dr. Muhammad Shamsuzzoha for technical assistance and their immense contribution and suggestions throughout the period of this work. Afterwards, I will be thankful to the “Department of Chemical Engineering, KFUPM” for providing me research opportunity to polish my abilities. Finally, no thanks can be enough to my friends who played a healthy role in my studies. Finally, special thanks to my parents, brothers, sisters and family for their encouragement and moral support. v TABLE OF CONTENTS ACKNOWLEDGMENTS ............................................................................................................. V TABLE OF CONTENTS ............................................................................................................. VI LIST OF TABLES ..................................................................................................................... VIII LIST OF FIGURES ...................................................................................................................... IX LIST OF ABBREVIATIONS ...................................................................................................... XI ABSTRACT ................................................................................................................................ XII XIII ............................................................................................................................... ملخص الرسالة CHAPTER 1 INTRODUCTION ................................................................................................. 1 1.1 Introduction to Distillation Operation ............................................................................................. 1 1.2 Material Balance on Distillation Column ......................................................................................... 8 1.3 Different Configurations for Distillation Column ........................................................................... 10 1.3.1 Simple Column Configuration ................................................................................................... 13 1.3.2 Complex Column Configuration ................................................................................................ 17 1.4 Control Strategies for Distillation Column ..................................................................................... 24 CHAPTER 2 OBJECTIVES ...................................................................................................... 27 CHAPTER 3 LITERATURE REVIEW ................................................................................... 28 CHAPTER 4 DESIGN OF DIVIDED WALL DISTILLATION COLUMN ......................... 45 4.1 Design of Divided-Wall Distillation Column ................................................................................... 46 vi 4.2 Heuristic Rules of Divided-Wall Distillation Column Design ........................................................... 47 CHAPTER 5 OPTIMAL OPERATION OF FOUR PRODUCT DIVIDED WALL (KAIBEL) DISTILLATION COLUMN ................................................................................... 49 5.1 Alcohol Mixture as Feed ................................................................................................................ 55 5.2 Hydrocarbon stream as Feed ........................................................................................................ 69 5.3 Aromatic Mixture as Feed ............................................................................................................. 81 CHAPTER 6 CONTROL OF DIVIDED WALL COLUMN ................................................... 93 6.1 Introduction to Process Control .................................................................................................... 93 6.2 Classification of Process Control Strategies ................................................................................... 95 6.3 Control of Dividing-Wall Distillation Column ................................................................................. 98 CHAPTER 7 CONCLUSION AND RECOMMENDATION ............................................... 108 7.1 Conclusions ................................................................................................................................. 108 7.2 Recommendation........................................................................................................................ 108 REFERENCES.......................................................................................................................... 109 VITAE ....................................................................................................................................... 112 vii LIST OF TABLES Table 1: General comparison of results for all distillation column configurations .......... 64 Table 2: Simulations results for Direct and Indirect Sequences ....................................... 76 Table 3: Simulation results for Distributed and Divided wall Distillation Column ......... 77 Table 4: Overall results obtained from all the possible distillation column sequences .... 80 Table 5: Simulations results obtained from Direct and Indirect Sequences ..................... 88 Table 6: Simulation results obtained from Distributed and Dividing-Wall Distillation Column .............................................................................................................................. 89 Table 7: Overall simulation results obtained from all possible distillation columns arrangements ..................................................................................................................... 92 Table 8: Controller used in the dynamic simulation and their objectives....................... 100 viii LIST OF FIGURES Figure 1: Process Flow Diagram (PFD) of a Binary Distillation Column .......................... 4 Figure 2 : Three Equilibrium Stages of a Distillation Column ........................................... 6 Figure 3: Block Diagram showing different configurations of distillation column ......... 12 Figure 4: Direct Sequence for Distillation Columns......................................................... 13 Figure 5: Indirect Sequence for Distillation Columns ...................................................... 14 Figure 6: Direct-Indirect Sequence for Distillation Columns ........................................... 15 Figure 7: Distributed Sequence for Distillation Columns................................................. 16 Figure 8: Side Rectifier Arrangement ............................................................................... 19 Figure 9: Side Stripper Arrangement ................................................................................ 20 Figure 10: Fully thermally coupled distillation column ................................................... 21 Figure 11: Divided -wall distillation column .................................................................... 22 Figure 12: Effect of liquid split ratio on reboiler duty ...................................................... 52 Figure 13: Effect of liquid split ratio on product composition ......................................... 53 Figure 14: Effect of vapor split ratio on product composition.......................................... 54 Figure 15: Direct Sequence for Distillation Columns....................................................... 56 Figure 16: Indirect Sequence for Distillation Columns .................................................... 57 Figure 17: Distributed Sequence for Distillation Columns .............................................. 58 Figure 18: Four Product Dividing-wall distillation (Kaibel) Column .............................. 59 Figure 19: Sub flow sheet Kaibel distillation column in Aspen HYSYS ......................... 60 Figure 20: Temperature Profile of Kaibel distillation column.......................................... 61 Figure 21: Composition profile throughout the distillation column ................................. 62 Figure 22: Final result window of Aspen HYSYS for Alcohol case ................................ 63 Figure 23: Four product Kaibel Distillation Column in Aspen HYSYS .......................... 66 Figure 24: Temperature profile throughout the main distillation column ........................ 67 Figure 25: Composition profile throughout the main distillation column .......................
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