Other Hydrocarbons Presented by Sachin Joshi Licensing Manager - PowerPoint PPT Presentation

Topic Advances in Distillation for Petrochemicals and Other Hydrocarbons Presented by Sachin Joshi Licensing Manager GTC Technology US, LLC

Improving Efficiency in Distillation Advanced Distillation GT-HIDS ℠ (Heat Integrated Differential Separation)

What is HIDS ? Heat Integrated Differential Separation (HIDS) • Direct Heat Integration by Vapor compression Propylene LP Column • Low pressure Top Section LLP Column (Rectification) Feed • Low-Low Pressure Bottom Section (Stripping) • Maximizes Relative Volatility Propane

HIDS Application • Applicable to close boiling pure component distillation • Preferentially for C 2 to C 5 component fractions • Reduces the CAPEX and OPEX compared to traditional distillation and Vapor Re-Compression (Heat Pump) • GTC patent protected

Case Study – C3 Distillation Traditional Process Options: High pressure distillation Mechanical Vapor (HP Distillation) Re-Compression (VRC)

Case Study - C 3 Distillation HP Distillation - Schematic • Typically Operates at 220 Psig@Top • Below feed or Bottom Section (Stripping) operates at higher pressure • Designed for utilizing cooling water • Highest Energy for Separation due to lower relative volatility

Case Study – C 3 Distillation Vapor Re-Compression (VRC) - Schematic

Case Study – C 3 Distillation Vapor Recompression (VRC) • Lower Pressure, typically operates at 160 Psig • Lower Temperature • Higher Relative Volatility compared to HP distillation • Compressor power is determined by reboiler temperature pinch and overall system Δ P, and overflash from hot reflux

Effect of Pressure on Relative Volatility Relative Volatility of Propylene to Propane 1.16 1.155 1.15 1.145 Relative Volatility 1.14 1.135 1.13 1.125 1.12 1.115 1.11 0 25 50 75 100 125 150 175 200 225 250 Pressure in Psig Relative Volatility VRC. HP Dist.

Case Study – C3 Distillation Process Options Traditional Process Options • High pressure distillation (HP Distillation) • Vapor recompression (VRC) HP Distillation VRC Base Higher than Base CAPEX Base Lower than Base OPEX • GTC Option – Heat Integrated Differential Separation

GT-HIDS ℠ - Heat Integrated Differential Separation LP Column LLP Column Bottom Section Top Section Feed Pressure Reducing Valve Propane Propylene

GT-HIDS ℠ Advantage Relative Volatility • Non linearity of relative volatility is addressed by Pressure Segregation – Pressure segregation between Stripping (Bottom) and rectification (Top) to optimize relative volatility – Temperature effect on Relative volatility is taken advantage – Significantly improved relative volatility Temperature Pinch • Direct coupling of top (rectification) and bottom (Stripping) section – Eliminates temperature pinch in the reboiler – Avoids overflash from hot reflux in VRC schemes – Thermally coupled columns reduces the overall energy consumption

GT-HIDS ℠ Operating Range for C 3 Separation Relative Volatility of Propylene to Propane 1.16 1.155 1.15 1.145 Relative Lolatility 1.14 1.135 1.13 1.125 1.12 1.115 1.11 60 80 100 120 140 160 180 200 220 240 Rectification Zone Stripping Zone Pressure in Psig (Top Section) (Bottom Section)

Case Study – C 3 Distillation Process Options Relative Volatility of Traditional Distillation methods & GT-HIDS 1.20E+00 HIDS - LLP Column - Bottom 1.18E+00 1.16E+00 Relative Volatility HIDS LP Column - Top 1.14E+00 VRC- FeedPoint HP DIST FeedPoint 1.12E+00 HP DIST-RV VRC Dist-RV 1.10E+00 HIDS Stripping HIDS-Rectification 1.08E+00 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 Stages

GT-HIDS ℠ Advantages • Maximizes the natural behavior of components to separate from each other • Lower energy compared to traditional distillation methods • Distillation done at best relative volatility efficiency point • Thermally coupled columns consume lower electricity compared to a VRC • Independent control of stripping and rectification zones offer stability and ease of operation

Case Study: C 3 Distillation • Feed Capacity = 30 KBPD Feed Specification Component Mol % Ethane 0.02 % Propane 20.86% Propylene 79.11% i-Butane 0.01%

Case Study : C 3 Distillation Product Specifications Propylene specification Propane specification • Recovery: 99.87% of • Recovery: 98% of Propylene Propane Component Mol % Component Mol % Ethane 0.02% Ethane 0.01% Propane 0.38% Propane 99.38% Propylene 99.58% Propylene 0.59% i-Butane 0.01% i-Butane 0.02%

Case Study: C 3 Distillation Overall Comparison: CAPEX & OPEX MVRC MVRC 100% 90% 80% 70% Cost 60% HIDS 50% 40% HIDS 30% 20% 10% 0% 1. 4Q of 2015 CAPEX OPEX 2.Electricity = $0.04 per KW-Hr HIDS 43% 85% 3.Cooling water = $0.075 per 1000 VRC 100% 100% gallons

C3 Splitter Debottleneck with HIDS New Compressor Column A Propylene New LLP Column Feed Column B Propane C3 Splitter Revamped to GT-HIDS ℠ Distillation C3 Splitter • Capacity Increment: by up to 50% • Energy Required: less by 40% compared to new system

C3 Splitter Debottleneck with HIDS Column A Propylene New LLP Column Feed Propane Vapor Recompression C3 Splitter C3 Splitter Revamped to GT-HIDS • Capacity Increment: by up to 50% • Energy Required: less by 40% compared to new system

Improving Fundamental Efficiency in Distillation Dividing Wall Columns

Case Study: Grassroots Mixed Xylenes Recovery Unit at a Refinery in Japan • TG had an existing unit which produced C7+ product for gasoline blending. • TG wanted to separate high purity petrochemicals (Toluene, Mixed Xylenes) from the feed. • TG decided for a DWC solution against a two column configuration because of lower CAPEX and lack of plot space.

Case Study: Mixed Xylenes Recovery

GT-DWC ℠ for Mixed Xylenes Recovery

Comparison: Two Column System vs DWC GT-DWC ℠ Two Column Parameter Units Configuration Configuration Mix-xylenes product Kg/hr 29,332 29,334 C8 aromatics wt%. 99.2 99.3 Reboiler duties MMkcal/hr. 21.6 17.2 Operating cost savings % - 20.0 Capital cost US $ MM 26.0 21.0 Steam savings due to heat TPH - 20.0 integration

TonenGeneral Mixed Xylenes Recovery Unit • Installation of GT-DWC ℠ Column at Chiba Refinery, Japan • Column Operational since March 2016

GT-DWC ℠ Internals Manufacturing - Korea GT-DWC ℠ Trays Testing of GT-DWC ℠ Internal Liquid Split Distributer

Summary • Advanced distillation applications are an overlooked means to reduce refinery energy consumption – GT-DWC reduces 20 – 30% OPEX through energy savings – GT-DWC reduces 20 – 30% CAPEX by requiring a single column for multi-component separation • GT-HIDS can make significant energy reduction and/or capacity enhancement with simpler modifications. 29

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