CHEE3004 Technical Recommendation

To: Gregory Siemon

From: Mohammad Izzat Abdul Aziz (43509331) Aiman Haziq Mohamad Zaini (43423325) Nur Hashimah
Hishamuddin (43413728)
Subject: Design Activity #4: Distillation Column Design
Date: 23th September 2015
Summary of project objective and context
The objectives of this project are to produce propylene with purity of 99.5% at the top product of the splitter and also
to have less than 10% of propylene at the bottom product in order to sell at value of $0.10/lb. A splitter with 216 trays
in the column must be designed to achieve the objectives and also to maximise the profit for the client. The optimum
operating condition of the splitter must be identified to maximise the profit.
Description of options considered
There are few options considered to achieve the objective of the project which are:
1. Manipulate column operating pressure to achieve optimum operating condition of the column by fixed the
reflux ratio at 16.4 and feed rate at 1350 lbmole/hr:
a) 260-280 psia
b) 280-300 psia
c) 300-320 psia
2. Manipulate feed flow rate to achieve the optimum operating condition of the column by fixed the reflux ratio
at 16.4 and used the optimum top pressure obtained from option 1:
a) 1500 lbmole/hr
b) 1350 lbmole/hr
c) 1200 lbmole/hr
Recommendation for process and/or equipment design
A propylene-propane splitter model was constructed on Aspen Hysys and all the options considered above were
analysed to achieve optimum operating conditions of the splitter. Based on the simulations done on the model (refer to
Results from the simulations on Aspen Hysys), option 1(a) showed the best result among all the options above as it
achieved the objectives of the project.
By setting up the top pressure of the column at 260 psia and 20 psia differential pressure over the column, the molar
composition obtained at the top product of the column was 0.997 which is higher than 0.995. The molar composition
of propylene at the bottom product of the column is less than 10% which is 0.0675. The reboiler and condenser duties
obtained by the simulation are also lie within the range which are 6.66x107Btu/hr and 7.03x107Btu/hr respectively.
These values show that the amount of energy consumption used by the splitter at top pressure of 260 psia is lower than
other top pressures.
The feed rate for this option is 1350lbmole/hr with feed pressure of 280 psia. Based on the calculations of profit,
$22008.5/hr will be obtained from this distillation column design.

Notes on risks associated with recommended design

Possible risks associated with recommended design:

Flooding:- occur by excessive vapour flow leads to liquid to be entrained in the vapour moving up the column
Entrainment & jet flood:- also caused by high vapour flow rate
Weeping:- caused by low vapor flow rate. The pressure exerted by the vapor is insufficient to hold up the
liquid on the tray.
Foaming:- the expansion of liquid due to passage of vapor or gas.

Version V1.2 20150724

CHEE3004 Unit Operations Design Decision Making Template

DESIGN ACTIVITY

Distillation Column Design

NAMES (STUDENT ID)

Mohammad Izzat Abdul

Aziz (43509331)

Semester 2, 2015
Date: 28/09/2015
Aiman Haziq Mohamad
Zaini (43423325)

Nur Hashimah
Hishamuddin (43413728)

1. FRAME THE DESIGN PROBLEM

1a. Purpose of the equipment or plant
to be designed

1b. Scope (list here any givens,

constraints, and boundaries to your
problem):

1c. Deliverables checklist:

What do you need to deliver for this
activity?
When does this work need to be
completed by?

Version V1.6 20150904

The client has requested to increase propylene purity from 99% to

99.5% at the top product.
The operating team have identified few issues such as:
The reboiler and condenser are subject to fouling.
The current maximum heat duties increased for fouled heat
exchanger compared to clean heat exchanger.
The vaporiser is subject to fouling and produce two phases,
liquid and vapor instead of fully saturated vapor.
The preliminary design must be submitted on Monday, 28th
September 2015 by 17:00pm.
The scope of this distillation column design is to achieve the level
of purity of propylene as requested by the client without changing
the number of trays in the column. The new number of stages and
new optimal feed location in current operating condition are
considered as out of scope.
The distillation column need to able to produce 99.5% of
propylene as a feed to the propylene plant.
The number of column trays is 216 and the number of theoretical
stages including partial reboiler is 184.
The distillation column must be operated at safety operating
condition:
Top pressure = 260-320 psia
Column differential pressure, DP = 20 psi (constant)
Reboiler duty = 610^7 7.2510^7 BTU/hr
Condenser duty = 610^7 7.810^7 BTU/hr
Feed quality condition = 60% vapour, 40% liquid with
unchanged feed composition
The propylene content in the bottom product must be less than
10%, otherwise the stream will be burnt as offspec and will
increase the profit loss.
The feed flow rate is 57 898 lb/hr with feed composition of 60%
propylene and 40% propane.
The top product is designed to produce 775 lbmole/hr of enriched
propylene stream with 16.4 reflux ratio.
The design heat duties for clean reboiler and condenser are 810^7
BTU/hr each.
If the team can produce propylene as pure as 99.5%, then the
propylene and propane can be sold at $0.60/lb and $0.10/lb.
The top product is valued at $0.5975/lb and the bottom product is
valued at $0.10/lb if the design specification can be achieved.
If the design cannot meet the design specification for the bottom
product composition, then there is no value or profit from the
bottom product.
Framing
Technical summary
Design template
P&ID drawing
MB&EBs including a copy of HYSYS model
Relevant output data/graph

CHEE3004 Unit Operations Design Decision Making Template

Semester 2, 2015

2. DEVELOP PROCESS EQUIPMENT CRITERIA: OBJECTIVES & PERFORMANCE MEASURES

2a. Objectives of equipment

2b. Performance measures or metrics

To produce 99.5% propylene at the top product

Propylene composition at the top product stream

Propylene content at bottom product must be less than

10%

Propylene composition at the bottom product stream

To maximise the profit for the propylene-propane

separation

Profit from the product based on the design specification

required by client

The distillation column must be operated a safety

operating condition

Compare input parameter from the HYSYS analysis with

the safety operating condition given

3. DESIGN CREATIVE OPTIONS

Small set (3-5), feasible, complete description, compelling, diverse
The design must meet the safety operating condition and design specification of the product to be feasible. The value
of reboiler heat duty and condenser heat duty must be within the range of the safety condition:
Reboiler duty = 610^7 7.2510^7 BTU/hr
Condenser duty = 610^7 7.810^7 BTU/hr
The design specification of the propylene are 99.5% propylene at the top product and less than 10% at the bottom
product. The ASPEN HYSYS analysis is done by manipulating several distillation column parameter to find best
operating condition to meet the requirement of the design specification and safety conditions:
1. Manipulate column operating pressure to achieve optimum operating condition of the column by fixed the
reflux ratio at 16.4 and feed rate at 1350 lbmole/hr:
260-280 psia
280-300 psia
300-320 psia
2. Manipulate feed flow rate by fixed the reflux ratio at 16.4 and used the optimum top pressure obtained from
option 1:
1500 lbmole/hr
1350 lbmole/hr
1200 lbmole/hr
4. ASSESS OPTION(S): repeat for all options of compelling interest
4a. What fundamental principles of
chemistry, physics and engineering is
this technology based on?

Version V1.6 20150904

Vapor liquid equilibrium Use Soave Redlich Kwong (SRK)

equation of state to calculate molar composition.
Mass balance - There is no reaction in the process, just merely a
separation process. No generation and consumption in the
process.
McCabe Thiele-method It is used to find number of theoretical
stages and real trays (but it is out of the design scope). The q-line
of the of the original design is used to compare with the q-line
current design.
Gravitational potential energy Liquid flow from the top to
bottom of the column to minimise the energy used in the plant
and maximise the use of potential energy.
Binary interaction
Equimolar overflow assumption
Murphree or overall column efficiency The number of
theoretical stages over the real tray
184
=
=
= 0.85

216

CHEE3004 Unit Operations Design Decision Making Template

4b. Briefly describe design method (e.g.
key sizing equations for short cut design)
(list critical assumptions on Log of
Assumptions over page)

McCabe Thiele method

Txy diagram plot from the vapor-liquid equilibrium data

Xy diagram:
(/ )( )
=
1 + (/ 1)
q-line:

=(
)
1
1

4c. Key design outputs for this option

Eg. pump type, duty

Version V1.6 20150904

Semester 2, 2015

Stripping operating line:

= ( 1 )

Rectifying operating line:

+1 = ( )

Reflux ratio equation:

+1 = (
) +
+1
+1

Propylene composition at the top product

Propylene composition at the bottom product
Product profit
Column operating pressure
Heat duties for reboiler and condenser
The best feed flowrate
Best column operating condition

CHEE3004 Unit Operations Design Decision Making Template

Semester 2, 2015
4c Analyse key input data/parameters
Sources of data should be identified here and in other parts of your design decision template. Cite data sources
using a numbered style and list references at the end of this template. Examples [1-3]
Parameter
Value range
Uncertainty level
Impact on metrics
Data source
Feed flowrate
57 898 lb/hr
(+/-) 5%
High, Direct - Propylene
Project brief
composition at the
top/bottom product
stream
Top product flowrate
775 lbmole/hr
(+/-) 10%
High, Direct - Propylene
Project brief
composition at the
top/bottom product
stream
Propylene feed
60%
(+/-) 10%
High, Direct - Propylene
Project brief
composition
composition at the
top/bottom product
stream
Propane feed composition
40%
(+/-) 10%
High, Direct - Propylene
Project brief
composition at the
top/bottom product
stream
Reflux ratio
16.4
(+/-) 10%
High, Direct - Propylene
Project brief
composition at the
top/bottom product
stream
Propylene top product
99.5%
(+/-) 10%
High, Direct - Propylene
Project brief
composition
composition at the
bottom product stream

610^7
7.2510^7
BTU/hr

(+/-) 5%

610^7 7.810^7 BTU/hr

(+/-) 5%

Rectifier operating
pressure

260-270 psia

(+/-) 10%

Stripper operating pressure

270-280 psia

(+/-) 10%

280 psia

(+/-) 10%

20 psi

(+/-) 10%

Reboiler heat duty

Condenser heat duty

Feed operating pressure

Column differential
pressure, DP

Version V1.6 20150904

High, Direct - Profit

from the product based
on the design
specification required by
client
High, Direct - Propylene
composition at the
top/bottom product
stream
High, Direct - Propylene
composition at the
top/bottom product
stream
High, Direct - Propylene
composition at the
top/bottom product
stream
High, Direct - Propylene
composition at the
top/bottom product
stream
Small, Direct Propylene composition
at the top/bottom
product stream
Small, Direct Propylene composition
at the top/bottom
product stream

Project brief

Project brief

Modelled in
HYSYS

Modelled in
HYSYS

Modelled in
HYSYS

Project brief

CHEE3004 Unit Operations Design Decision Making Template

Number of column trays
216
(+/-) 10%

Vapor feed composition

60%

(+/-) 10%

Liquid feed composition

40%

(+/-) 10%

Relative volatility,

1.1

(+/-) 20%

Semester 2, 2015
High, Direct - Propylene
Project brief
composition at the
top/bottom product
stream
High, Direct - Propylene
Project brief
composition at the
top/bottom product
stream
High, Direct - Propylene
Project brief
composition at the
top/bottom product
stream
High, Direct - Propylene From MBEB 4
composition at the
top/bottom product
stream
High, Direct The
number of theoretical
stages and real trays

Top product value

Bottom product value (if

<10%)

$0.5975/lb

$0.10/lb

High, Direct - Profit

from the product based
on the design
specification required by
client
High, Direct - Profit
from the product based
on the design
specification required by
client
High, Direct - Profit
from the product based
on the design
specification required by
client

Project brief

Project brief

5. EVALUATE SOLUTION/DESIGN
5a. Which of the options is mostly likely** to meet the design objectives? Answer this question by ranking the
options in the table below and justifying your ranking by explaining the advantages or disadvantages of the options.
**likely used here to convey there always uncertainty in success of designs until the thing is built, operated etc

Ranked Options
- include name or brief description
1.Operating pressure = 260-280 psia
(The best operating pressure)

2.Operating pressure = 280-300 psia

3.Operating pressure = 300-320 psia

Version V1.6 20150904

Advantages

Disadvantages

Reboiler and condenser heat duties

within range of safety condition

Propylene composition at top and

bottom product achieve the product
specification.
Reboiler and condenser heat duties
within range of safety condition
Propylene composition at top and
bottom product achieve the product
specification.
-

Cannot be solved in ASPEN

HYSYS

CHEE3004 Unit Operations Design Decision Making Template

4.The best feed flowrate = 1500
Reboiler and condenser heat duties
lbmole/hr
within range of safety condition

5.The best feed flowrate = 1350

lbmole/hr
(The best feed flowrate)

6. The best feed flowrate = 1200

lbmole/hr

5b. What is your recommended

option? (restate it here explicitly)

5c. Is the solution complete?

Propylene composition at top and

bottom product achieve the 99.5%
product specification.
Reboiler and condenser heat duties
within range of safety condition
Propylene composition at top and
bottom product achieve the product
specification.
Reboiler and condenser heat duties
within range of safety condition

Semester 2, 2015
Propylene composition at bottom
product do not achieve less than
10% product specification.

Propylene composition at top

product do not achieve 99.5%
product specification.

Propylene composition at bottom

product achieve less than 10%
product specification.
The best operation condition to achieve product specification, operated
within safety operating condition and will give higher profit:
Operating pressure = 260-280 psia
The best feed flowrate = 1350 lbmole/hr
Yes. The distillation column design meet the safety condition requirement
and propylene composition at top and bottom product.
The result from the analysis:
Operating pressure = 260-280 psia
The best feed flowrate = 1350 lbmole/hr
Propylene composition:
Top product = 99.7%
Bottom product = 6.75%
Profit from the product:
= (3.26 104
=

$ 0.5975
$ 0.1
)(
) + (2.53 104 ) (
)

$ 22008.5

5d. Which assumptions need to be

Differential pressure, DP
validated or what data needs to be
Feed composition
confirmed?
Relative volatility
5e. Is a redesign, refinement or
No because the recommended design has achieved the objectives of the
optimization of design required to
project.
meet objectives and satisfy
constraints?
5. COMMUNICATE RESULTS
Who needs to be informed of the
Distillation column operating team
outcome from this design activity?
Operator of the propylene plant
The client
My boss
Describe what information needs to be
The best operating condition to achieve design specification
communicated?
The amount of profit made
The amount of propylene produced
Version V1.6 20150904

CHEE3004 Unit Operations Design Decision Making Template

Semester 2, 2015
What is the next step required in the
Distillation column, reboiler, condenser and vaporiser must be
design or project cycle?
cleaned and maintain by maintenance team to get the best
operating condition.

1
2
3
4
5

LOG OF ASSUMPTIONS
Assume constant differential pressure, DP = 20 psi throughout the column
Assume fixed top product stream flow rate = 775 lbmole/hr
Use of Soave-Redlich -Kwong (SRK) equation of state to solve vapor-liquid equilibrium
In HYSYS model, no vaporiser duty required as the input parameter in the modelling analysis. The feed
composition is fixed to 60% propylene, 40% propane.
The relative volatility is constant, = 1.1

REFERENCES
1.Perry, Robert H, Doon W Green, and James O Maloney. Perry's Chemical Engineer's Platinum Edition Perry's
Chemical Engineers' Handbook. New York: McGraww-Hill, 1999. Print.
2.Luyben, William L, P Buckley, and J. P Shunta. Design Of Distillation Column Control Systems. San Diego:
Butterworth-Heinemann [Imprint], 1985. Print.
3.Towler, G. and R.K. Sinnott, Chemical engineering design: principles, practice, and economics of plant and process
design. Vol. 2nd; 2. 2013, Oxford; Waltham, MA: Butterworth-Heinemann.
4. Hamid, Mohd. Kamaruddin Abd. Aspen HYSYS: An Introduction To Chemical Engineering Simulation. Print.

Version V1.6 20150904

Graphs and results from simulations on Aspen Hysys

Change in feed conditions on McCabe-Thiele drawing.

xy Plot for propylene-propane

y, mole fraction of propylene

1.2
1
y = -0.67x + 1.002
0.8
0.6

Original q-line

0.4

New q-line

0.2
0
0

0.2

0.4

0.6

0.8

1.2

x, mole fraction of propylene

Change of temperature over the column (including reboiler)

Temperature change over the column

135
130

Temperature (F)

125
120
115
110
105
0

50

100

150

Number of Stages

200

250

Liquid and Vapour flows change over the column

Liquid and Vapour Flows change over the

column
Flow rate (lb-mol/hr)

13600
13400
13200
13000
12800

Liquid Flow Rate

12600

Vapour Flow Rate

12400
12200
12000
0

50

100

150

200

Number of Stages

Results from the simulations on Aspen Hysys

Nomenclature & Legend:
Propylene A
Propane B
- Important
- Variables
Condition 1a(Changing Operating Pressure):
Input:

Feed
Flowrate 1350lb-mole/hr
Mole fraction components:
Xa = 0.6
Xb = 0.4
Vapour composition 0.6
Liquid composition 0.4
Pressure 280psia

Overhead Stream
Flowrate 775lb-mole/hr

250

System
Number of stages 216 (real condition)
Pressure 260 to 270psia for rectifier column and 270 to 280psia for stripper column.
Reflux ratio - 16.4

Output:

Heat duty for reboiler & condenser (must be within range 6x10^7 7.25x10^7 BTU/Hr for
condenser and 6x10^7 - 7.8x10^7 BTU/Hr for reboiler
Molar fraction of propylene for bottom stream (must be less than 10%)
Molar fraction of propylene for overhead stream (must be less than 99.5%)
Flow rate for bottom stream
Temperature for the overall system (eg: feed, overhead stream, bottom stream)

Results:

Heat duty condenser = 7.03x10^7 Btu/hr (6x10^7 - 7.8x10^7 BTU/Hr)

Heat duty reboiler = 6.66x10^7Btu/hr (6x10^7 7.25x10^7 BTU/Hr)
Molar fraction propylene at bottom stream = 0.0675 (6.75%) < 10%
Molar fraction propylene at overhead stream = 0.997(99.7%) >99.5%

Condition 1b(Changing Operating Pressure):

Input:

Feed
Flowrate 1350lb-mole/hr
Mole fraction components:
Xa = 0.6
Xb = 0.4
Vapour composition 0.6
Liquid composition 0.4
Pressure 300psia

Overhead Stream
Flowrate 775lb-mole/hr

System
Number of stages 216 (real condition)
Pressure 280 to 290psia for rectifier column and 290 to 300psia for stripper column.
Reflux ratio - 16.4

Output:

Heat duty for reboiler & condenser

Molar fraction of propylene for bottom stream
Molar fraction of propylene for overhead stream
Flow rate for bottom stream
Temperature for the overall system (eg: feed, overhead stream, bottom stream)

Results:

Heat duty condenser = 7.17x10^7Btu/hr (6x10^7 - 7.8x10^7 BTU/Hr)

Heat duty reboiler = 6.74x10^7Btu/hr (6x10^7 7.25x10^7 BTU/Hr)
Molar fraction propylene = 0.0675 (6.75%) < 10%
Molar fraction propylene at overhead stream = 0.997(99.7%) >99.5%

Condition 1c (Find the suitable range of pressure to get 775lb-mole/hr of 0.995 propylene):
Input:

Feed
Flowrate 1350lb-mole/hr
Mole fraction components:
Xa = 0.6
Xb = 0.4
Vapour composition 0.6
Liquid composition 0.4
Pressure 320psia

Overhead Stream
Flowrate 775lb-mole/hr

System
Number of stages 216 (real condition)
Pressure 300 to 310psia for rectifier column and 310 to 320psia for stripper column.
Reflux ratio - 16.4

Output:

Heat duty for reboiler & condenser

Molar fraction of propylene for bottom stream
Molar fraction of propylene for overhead stream
Flow rate for bottom stream
Temperature for the overall system (eg: feed, overhead stream, bottom stream)

Results:

For this range of pressure, APSEN HYSYS still cannot solve the modelling problem even after
several thousand of iterations. So it is concluded that range of pressure of 300 to 320 psia is
not suitable for this distillation column operating process.

Conclusion:
Both range of pressure in case 1a and 1b can be used for the operation to obtain the desired result
as it falls in the safe operating condition. Between those two, the heat duty required in case 1a is a
bit lower than in case 1b. Therefore we choose pressure range as in case 1a which is from 260 to
280psia with feed stream having a pressure of 280psia.
Condition 2a (Changing Feed Flowrate):
Input:

Feed
Flowrate 1200lb-mole/hr
Mole fraction components:
Xa = 0.6
Xb = 0.4
Vapour composition 0.6
Liquid composition 0.4
Pressure 280psia

Overhead Stream
Flowrate 775lb-mole/hr

System
Number of stages 216 (real condition)
Pressure 260 to 270psia for rectifier column and 270 to 280psia for stripper column.
Reflux ratio 16.4

Output:

Heat duty for reboiler and condenser

Molar fraction of propylene for bottom stream
Flow rate for bottom stream
Temperature for the overall system (eg: feed, overhead stream, bottom stream)

Results:

Heat duty reboiler = 6.92x10^7Btu/hr (6x10^7 7.25x10^7 BTU/Hr)

Heat duty condenser = 7.29x10^7Btu Btu/hr (6x10^7 - 7.8x10^7 BTU/Hr)
Molar fraction propylene at bottom stream = 0.0016 (0.16%) > 10%
Molar fraction propylene at overhead stream = 0.93 (99.3%) < 99.5% X

Condition 2b (Changing Feed Flowrate):

Input:

Feed
Flowrate 1500lb-mole/hr
Mole fraction components:
Xa = 0.6
Xb = 0.4
Vapour composition 0.6
Liquid composition 0.4
Pressure 280psia

Overhead Stream
Flowrate 775lb-mole/hr

System
Number of stages 216 (real condition)
Pressure 260 to 270psia for rectifier column and 270 to 280psia for stripper column.
Reflux ratio 16.4

Output:

Heat duty for reboiler and condenser

Molar fraction for bottom stream
Flow rate for bottom stream
Temperature for the overall system (eg: feed, overhead stream, bottom stream)

Results:

Heat duty reboiler = 6.91x10^7Btu/hr (6x10^7 7.25x10^7 BTU/Hr)

Heat duty condenser = 7.32x10^7Btu/hr (6x10^7 - 7.8x10^7 BTU/Hr)
Molar fraction propylene at bottom stream = 0.176 (17.6%) > 10% X
Molar fraction propylene at overhead stream = 0.997(99.7%) >99.5%

Conclusion:
The most suitable feed flow rate is at 1350lb-mole/hr which is the given flow rate condition as it can
meet all the required operating condition. The result from simulation can be seen in condition 1a).

PI

TI

TI
Cold fluid

Symbol

Descriptions

TI

Temperature indicator

PI

Pressure indicator

FI

Flow indicator

LI

Level indicator

Sample point

Condenser
C-101

TI

Hot fluid

Distillate drum
D-102

LI

TI

PI

FI

DP
Top product

TI

PI

FI

Distillation column
D-101

Feed

Pump 3
P-103

FI
TI
PI

Vaporiser
V-101

Pump 2
P-102

TI

DP

TI

LI

PI

Steam
TI
FI

Reboiler
R-101

Steam conden sate

TI

FI

UNIVERSITY OF QUEENSLAND
Proposed design of Distillation column
Bottom product

PIPING & INSTRUMENTATION DIAGRAM

DISTILLATION COLUMN
DRAWN BY: Mohammad
Izzat Abdul Aziz
CHECKED BY: Group 17

SIZE

DATE

DWG NO

A4

28/09/2015
NTS

CHEE3004-P&ID-001

SCALE

SHEET

REV

1 OF 1

Pump 1
P-101