Optimal design of extractive dividing-wall column using an efficient equation-oriented approach

Abstract

The extractive dividing-wall column (EDWC) is one of the most efficient technologies for separation of azeotropic or close boiling-point mixtures, but its design is fairly challenging. In this paper we extend the hybrid feasible path optimisation algorithm (Ma Y, McLaughlan M, Zhang N, Li J. Computers & Chemical Engineering, 2020, 143: 107058) for such optimal design. The tolerances-relaxation integration method is refined to allow for long enough integration time that can ensure the solution of the pseudo-transient continuation simulation close to the steady state before the required tolerance is used. To ensure the gradient and Jacobian information available for optimisation, we allow a relaxed tolerance for the simulation in the sensitivity analysis mode when the simulation diverges under small tolerance. In addition, valid lower bounds on purity of the recycled entrainer and the vapour flow rate in column sections are imposed to improve computational efficiency. The computational results demonstrate that the extended hybrid algorithm can achieve better design of the EDWC compared to those in literature. The energy consumption can be reduced by more than 20% compared with existing literature report. In addition, the optimal design of the heat pump assisted EDWC is achieved using the improved hybrid algorithm for the first time.

Graphical abstract

Keywords

design / extractive dividing-wall column / equation-oriented optimisation / pseudo-transient continuation model / hybrid algorithm

References

[1] Gerbaud V, Rodriguez Donis I, Hegely L, Lang P, Denes F, You X. Review of extractive distillation. Process design, operation, optimization and control. Chemical Engineering Research & Design, 2019, 141: 229–271

[2] Schultz M A, Stewart D G, Harris J M, Rosenblum S P, Shakur M S, O’Brien D E. Reduce costs with dividing-wall columns. Chemical Engineering Progress, 2002, 98: 64–71

[3] Hernández S. Analysis of energy-efficient complex distillation options to purify bioethanol. Chemical Engineering & Technology, 2008, 31(4): 597–603

[4] Tavan Y, Riazi S H, Nozohouri M. Energy optimization and comparative study of pre- and post-fractionator extractive dividing wall column for the CO₂ ethane azeotropic process. Energy Conversion and Management, 2014, 79: 590–598

[5] Staak D, Grützner T. Process integration by application of an extractive dividing-wall column: an industrial case study. Chemical Engineering Research & Design, 2017, 123: 120–129

[6] Cordeiro G M, de Figueirêdo M F, Ramos W B, Sales F A, Brito K D, Brito R P. Systematic strategy for obtaining a dividing-wall column applied to an extractive distillation process. Industrial & Engineering Chemistry Research, 2017, 56(14): 4083–4094

[7] Kiss A A, Suszwalak D J P C. Enhanced bioethanol dehydration by extractive and azeotropic distillation in dividing-wall columns. Separation and Purification Technology, 2012, 86: 70–78

[8] Bravo Bravo C, Segovia Hernández J G, Gutiérrez Antonio C, Durán A L, Bonilla Petriciolet A, Briones Ramírez A. Extractive dividing wall column: design and optimization. Industrial & Engineering Chemistry Research, 2010, 49(8): 3672–3688

[9] Gutiérrez Guerra R, Segovia Hernández J G, Hernández S. Reducing energy consumption and CO₂ emissions in extractive distillation. Chemical Engineering Research & Design, 2009, 87(2): 145–152

[10] Biegler L T. New nonlinear programming paradigms for the future of process optimization. AIChE Journal. American Institute of Chemical Engineers, 2017, 63(4): 1178–1193

[11] Powell M J D. A fast algorithm for nonlinearly constrained optimization calculations. In: Watson G A, ed. Proceedings of the Numerical Analysis. Berlin: Springer, 1978, 144–157

[12] Aspen Technology Inc. Aspen Plus User’s Guide Version V8.8. 2015

[13] Loy Y Y, Lee X L, Rangaiah G P. Bioethanol recovery and purification using extractive dividing-wall column and pressure swing adsorption: an economic comparison after heat integration and optimization. Separation and Purification Technology, 2015, 149: 413–427

[14] Yang A, Wei R, Sun S, Wei S, Shen W, Chien I L. Energy-saving optimal design and effective control of heat integration-extractive dividing wall column for separating heterogeneous mixture methanol/toluene/water with multiazeotropes. Industrial & Engineering Chemistry Research, 2018, 57(23): 8036–8056

[15] Vikse M, Watson H A J, Kim D, Barton P I, Gundersen T. Optimization of a dual mixed refrigerant process using a nonsmooth approach. Energy, 2020, 196: 116999

[16] Dowling A W, Biegler L T. A framework for efficient large scale equation-oriented flowsheet optimization. Computers & Chemical Engineering, 2015, 72: 3–20

[17] Ma Y, Luo Y, Yuan X. Simultaneous optimization of complex distillation systems with a new pseudo-transient continuation model. Industrial & Engineering Chemistry Research, 2017, 56(21): 6266–6274

[18] Ma Y, Luo Y, Ma X, Yang T, Chen D, Yuan X. Fast algorithms for flowsheet simulation and optimization using psdueo-transient models. Industrial & Engineering Chemistry Research, 2018, 57(42): 14124–14142

[19] Waltermann T, Grueters T, Muenchrath D, Skiborowski M. Efficient optimization-based design of energy-integrated azeotropic distillation processes. Computers & Chemical Engineering, 2020, 133: 106676

[20] Ma Y, McLaughlan M, Zhang N, Li J. Novel feasible path optimization algorithms using steady-state and dynamic models. Computers & Chemical Engineering, 2020, 143: 107058

[21] Luyben W L. Control of the maximum-boiling acetone/chloroform azeotropic distillation System. Industrial & Engineering Chemistry Research, 2008, 47(16): 6140–6149

[22] Kiss A A, Ignat R M. Innovative single step bioethanol dehydration in an extractive dividing-wall column. Separation and Purification Technology, 2012, 98: 290–297

[23] Luo H, Bildea C S, Kiss A A. Novel heat-pump-assisted extractive distillation for bioethanol purification. Industrial & Engineering Chemistry Research, 2015, 54(7): 2208–2213

[24] Pattison R C, Baldea M. Equation-oriented flowsheet simulation and optimization using pseudo-transient models. AIChE Journal. American Institute of Chemical Engineers, 2014, 60(12): 4104–4123

[25] Pattison R C, Gupta A M, Baldea M. Equation-oriented optimization of process flowsheets with dividing-wall columns. AIChE Journal. American Institute of Chemical Engineers, 2016, 62(3): 704–716

[26] Dowling A W, Biegler L T. Rigorous optimization-based synthesis of distillation cascades without integer variables. Computer-Aided Chemical Engineering, 2014, 33: 55–60

[27] Biegler L T. Nonlinear Programming: Concepts, Algorithms, and Applications to Chemical Processes. Philadelphia: Society for Industrial and Applied Mathematics, 2010, 160–161

[28] Biegler L T, Hughes R R. Feasible path optimization with sequential modular simulators. Computers & Chemical Engineering, 1985, 9(4): 379–394

[29] Higham N J. Accuracy and Stability of Numerical Algorithms. 2nd ed. Philadelphia: Society for Industrial and Applied Mathematics, 2002, 3–4

[30] Aspen Technology Inc. Aspen Custom Modeler User’s Guide Version V8.8. 2015

[31] Python Software Foundation. Python language reference version 3.6. 2016

[32] Kraft D. A software package for sequential quadratic programming. Braunschweig, Köln: DFVLR, 1988

[33] Aurangzeb M, Jana A K. A novel heat integrated extractive dividing wall column for ethanol dehydration. Industrial & Engineering Chemistry Research, 2019, 58(21): 9109–9117

[34] Suszwalak D J P C, Kiss A A. Enhanced bioethanol dehydration in extractive dividing-wall columns. Computer-Aided Chemical Engineering, 2012, 30: 667–671

[35] Aurangzeb M, Jana A K. Double-partitioned dividing wall column for a multicomponent azeotropic system. Separation and Purification Technology, 2019, 219: 33–46

[36] Luyben W L. Distillation Design and Control Using Aspen Simulation. Hoboken: John Wiley & Sons, 2006, 87–89

RIGHTS & PERMISSIONS

The Author(s) 2020. This article is published with open access at link.springer.com and journal.hep.com.cn