Synthesis of heat-integrated distillation sequences with intermediate heat exchangers

doi:10.11949/0438-1157.20221352

Abstract

Abstract:

This study addressed the synthesis problem of distillation sequences considering intermediate heat exchanger (IHE). Using the stochastic optimization strategy, a new method was proposed to synthesize heat-integrated distillation sequences with intermediate heat exchanger (IHE-HIDSs). The binary variables 0/1 are introduced to define whether the IHE is used in the corresponding merge point of two separation tasks in one distillation column. In this way, the synthesis problem is formulated as an implicit mixed-integer nonlinear programming (MINLP) problem, and could be solved by using the hybrid simulated annealing and particle-swarm optimization (SA-PSO) algorithm with the goal to minimize the total annual cost (TAC) of the distillation process. To illustrate the proposed method, two distillation sequence syntheses of five-component alcohols and five-component alkanes were investigated. The results show that IHE-HIDS has a lower TAC than the distillation sequence considering both thermal coupling and energy integration. In addition, the method proposed in this paper can obtain multiple separation sequence solutions with high probability in a reasonable computational time.

Key words: optimization, distillation, algorithm, intermediate heat exchanger, energy integration, sequential synthesis

摘要：

针对考虑中间换热器（IHE）的精馏序列合成问题，提出基于随机优化策略的能量集成非清晰精馏序列（IHE-HIDSs）合成方法。通过对精馏序列分离任务合并处引入二元0/1变量表示是否存在IHE，以精馏序列的年总成本（TAC）为优化目标，建立了该合成问题的隐式混合整数非线性规划模型（MINLP），通过模拟退火和粒子群优化（SA-PSO）混合随机优化算法进行求解。为验证在精馏序列合成中同时考虑IHE的必要性以及所提出合成方法的有效性，对五组分醇类混合物和五组分烷烃类混合物两个算例的精馏序列合成问题进行了研究。结果表明，相比同时考虑热耦合和能量集成的精馏序列，IHE-HIDS具有更低的TAC。此外，所提出的方法可以在合理的计算时间内以高概率获得多个分离序列方案。

关键词: 优化, 蒸馏, 算法, 中间换热器, 能量集成, 序列合成

CLC Number:

TQ 028.3

Haiou YUAN, Fangjun YE, Shuo ZHANG, Yiqing LUO, Xigang YUAN. Synthesis of heat-integrated distillation sequences with intermediate heat exchangers[J]. CIESC Journal, 2023, 74(2): 796-806.

袁海鸥, 叶方俊, 张硕, 罗祎青, 袁希钢. 考虑中间换热器的能量集成精馏序列合成[J]. 化工学报, 2023, 74(2): 796-806.

Figures/Tables 14

References 38

1	Sholl D S, Lively R P. Seven chemical separations to change the world[J]. Nature, 2016, 532(7600): 435-437.
2	Humphrey J L, Siebert A F. Separation technologies: an opportunity for energy savings[J]. Chemical Engineering Progress, 1992, 88(3): 32-41.
3	Jana A K. Heat integrated distillation operation[J]. Applied Energy, 2010, 87(5): 1477-1494.
4	Kiss A A. Towards energy efficient distillation technologies — making the right choice[J]. Energy, 2012, 47(1): 531-542.
5	Yeomans H, Grossmann I E. Disjunctive programming models for the optimal design of distillation columns and separation sequences[J]. Industrial & Engineering Chemistry Research, 2000, 39(6): 1637-1648.
6	Zhang L B, Linninger A A. Towards computer-aided separation synthesis[J]. AIChE Journal, 2006, 52(4): 1392-1409.
7	Wang F, Luo Y Q, Yuan X G. A formulation methodology for multicomponent distillation sequences based on stochastic optimization[J]. Chinese Journal of Chemical Engineering, 2016, 24(9): 1229-1235.
8	Leeson D. Simultaneous design of separation sequences and whole process energy integration[J]. Chemical Engineering Research and Design, 2017, 125: 166-180.
9	Zhang S. Simultaneous optimization of nonsharp distillation sequences and heat integration networks by simulated annealing algorithm[J]. Energy, 2018, 162: 1139-1157.
10	Caballero J A, Grossmann I E. Optimal synthesis of thermally coupled distillation sequences using a novel MILP approach[J]. Computers & Chemical Engineering, 2014, 61: 118-135.
11	Caballero J A, Grossmann I E. Structural considerations and modeling in the synthesis of heat-integrated-thermally coupled distillation sequences[J]. Industrial & Engineering Chemistry Research, 2006, 45(25): 8454-8474.
12	陆恩锡, 李小玲, 吴震. 蒸馏过程中间再沸器与中间冷凝器[J]. 化学工程, 2008, 36(11): 74-78.
	Lu E X, Li X L, Wu Z. Inter-reboiler and inter-condenser in distillation[J]. Chemical Engineering (China), 2008, 36(11): 74-78.
13	Alcántara-Avila J R, Tanaka M, Márquez C R, et al. Design of a multitask reactive distillation with intermediate heat exchangers for the production of silane and chlorosilane derivates[J]. Industrial & Engineering Chemistry Research, 2016, 55(41): 10968-10977.
14	Li Y D, Ye Q, Wang N G, et al. Energy-efficient extractive distillation combined with heat-integrated and intermediate reboilers for separating acetonitrile/isopropanol/water mixture[J]. Separation and Purification Technology, 2021, 262: 118343.
15	Agrawal R, Herron D M. Efficient use of an intermediate reboiler or condenser in a binary distillation[J]. AIChE Journal, 1998, 44(6): 1303-1315.
16	Agrawal R, Herron D M. Intermediate reboiler and condenser arrangement for binary distillation columns[J]. AIChE Journal, 1998, 44(6): 1316-1324.
17	Björn I N. Simulation and experimental study of intermediate heat exchange in a sieve tray distillation column[J]. Computers & Chemical Engineering, 2002, 26(4/5): 499-505.
18	许良华, 陈大为, 罗祎青, 等. 带有中间热集成的精馏塔序列及其性能[J]. 化工学报, 2013, 64(7): 2503-2510.
	Xu L H, Chen D W, Luo Y Q, et al. Intermediate heat-integrated sequence of distillation columns and its energy-saving property[J]. CIESC Journal, 2013, 64(7): 2503-2510.
19	An W Z, Yu F J, Dong F L, et al. Simulated annealing approach to the optimal synthesis of distillation column with intermediate heat exchangers[J]. Chinese Journal of Chemical Engineering, 2008, 16(1): 30-35.
20	Thompson R W, King C J. Systematic synthesis of separation schemes[J]. AIChE Journal, 1972, 18(5): 941-948.
21	Stephanopoulos G, Westerberg A W. Studies in process synthesis(Ⅱ): Evolutionary synthesis of optimal process flowsheets[J]. Chemical Engineering Science, 1976, 31(3): 195-204.
22	Qian Y, Lien K M. Rule based synthesis of separation systems by predictive best first search with rules represented as trapezoidal numbers[J]. Computers & Chemical Engineering, 1995, 19(11): 1185-1205.
23	Gooty R T. An MINLP formulation for the optimization of multicomponent distillation configurations[J]. Computers & Chemical Engineering, 2019, 125: 13-30.
24	Yeomans H. A systematic modeling framework of superstructure optimization in process synthesis[J]. Computers & Chemical Engineering, 1999, 23(6): 709-731.
25	Caballero J A. Design of distillation sequences: from conventional to fully thermally coupled distillation systems[J]. Computers & Chemical Engineering, 2004, 28(11): 2307-2329.
26	Caballero J A, Grossmann I E. Synthesis of complex thermally coupled distillation systems including divided wall columns[J]. AIChE Journal, 2013, 59(4): 1139-1159.
27	Biegler L T. Retrospective on optimization[J]. Computers & Chemical Engineering, 2004, 28(8): 1169-1192.
28	Shah V H, Agrawal R. A matrix method for multicomponent distillation sequences[J]. AIChE Journal, 2010, 56(7): 1759-1775.
29	Wang X H, Li Y G. Synthesis of multicomponent products separation sequences via stochastic GP method[J]. Industrial & Engineering Chemistry Research, 2008, 47(22): 8815-8822.
30	Jain S, Smith R, Kim J K. Synthesis of heat-integrated distillation sequence systems[J]. Journal of the Taiwan Institute of Chemical Engineers, 2012, 43(4): 525-534.
31	Yuan X G, An W Z. Synthesis of heat integrated complex distillation systems via stochastic optimization approaches[J]. Chinese Journal of Chemical Engineering, 2002, 10(5): 495-507.
32	An W Z. A simulated annealing-based approach to the optimal synthesis of heat-integrated distillation sequences[J]. Computers & Chemical Engineering, 2009, 33(1): 199-212.
33	Zhang S. Synthesis of simultaneously heat integrated and thermally coupled nonsharp distillation sequences based on stochastic optimization[J]. Computers & Chemical Engineering, 2019, 127: 158-174.
34	Zhang S, Luo Y Q, Yuan X G. A novel stochastic optimization method to efficiently synthesize large-scale nonsharp distillation systems[J]. AIChE Journal, 2021, 67(9): e17328.
35	Giridhar A. Synthesis of distillation configurations ( Ⅰ ) : Characteristics of a good search space[J]. Computers & Chemical Engineering, 2010, 34(1): 73-83.
36	安维中. 基于随机优化的复杂精馏系统综合研究[D]. 天津: 天津大学, 2003.
	An W Z. Synthesis of complex distillation systems based on stochastic optimization[D]. Tianjin: Tianjin University, 2003.
37	Metropolis N, Rosenbluth A W, Rosenbluth M N, et al. Equation of state calculations by fast computing machines[J]. The Journal of Chemical Physics, 1953, 21(6): 1087-1092.
38	Turton R, Bailie R C, Whiting W B, et al. Analysis, Synthesis and Design of Chemical Processes[M]. New York: Pearson Education, 2008: 231-266.

Separation task		p/MPa	R	ξ_LK	ξ_HK	V/(kmol/h)	T_D/K	T_B/K	Q_c/(GJ/h)	Q_r/(GJ/h)
1	ABC\|BCDE	0.10	1.10	0.980	0.020	486.15	355.52	379.05	19.320	20.346
2	AB\|BC	0.10	1.26	0.980	0.020	375.51	352.58	—	14.670	—
3	BCD\|E	0.40	1.56	0.9800	0.020	498.25	413.14	441.18	18.630	18.848
4	A\|B	0.38	9.30	0.980	0.020	1221.85	389.07	403.11	42.964	30.007
5	BC\|CD	0.10	5.65	0.997	0.005	375.51	—	377.45	—	15.610
6	B\|C	0.38	8.52	0.980	0.020	343.49	—	—	—	—
7	C\|D	0.38	2.90	0.980	0.020	343.49	—	428.15	—	12.755
{IHE}：{0, 1, 0}：2-5 (0)、4-6 (1)、6-7 (0) TAC：376595.35 USD/a
年度设备费：81384.51 USD/a；年度操作费：295210.84 USD/a
中间组分回收率：ABC\|BCDE：ξ_B = 0.8154、ξ_C = 0.2653；AB\|BC：ξ_B = 0.7351；BC\|CD：ξ_C = 0.3102 能量匹配：20.346 GJ/h (4→1), 15.610 GJ/h (4→5), 18.630 GJ/h (3→4)

Separation task		p/MPa	R	ξ_LK	ξ_HK	V/(kmol/h)	T_D/K	T_B/K	Q_c/(GJ/h)	Q_r/(GJ/h)
1	ABC\|BCDE	0.10	1.10	0.980	0.020	486.15	355.52	379.05	19.320	20.346
2	AB\|BC	0.10	1.26	0.980	0.020	375.51	352.58	—	14.670	—
3	BCD\|E	0.40	1.56	0.9800	0.020	498.25	413.14	441.18	18.630	18.848
4	A\|B	0.38	9.30	0.980	0.020	1221.85	389.07	403.11	42.964	30.007
5	BC\|CD	0.10	5.65	0.997	0.005	375.51	—	377.45	—	15.610
6	B\|C	0.38	8.52	0.980	0.020	343.49	—	—	—	—
7	C\|D	0.38	2.90	0.980	0.020	343.49	—	428.15	—	12.755
{IHE}：{0, 1, 0}：2-5 (0)、4-6 (1)、6-7 (0) TAC：376595.35 USD/a
年度设备费：81384.51 USD/a；年度操作费：295210.84 USD/a
中间组分回收率：ABC\|BCDE：ξ_B = 0.8154、ξ_C = 0.2653；AB\|BC：ξ_B = 0.7351；BC\|CD：ξ_C = 0.3102 能量匹配：20.346 GJ/h (4→1), 15.610 GJ/h (4→5), 18.630 GJ/h (3→4)

合成方案	TAC/(USD/a)	设备费/(USD/a)	操作费/(USD/a)
IHE-HIDS	376595.35	81384.51	295210.84
HITCDS	379231.29	63343.43	315887.86

合成方案	TAC/(USD/a)	设备费/(USD/a)	操作费/(USD/a)
IHE-HIDS	376595.35	81384.51	295210.84
HITCDS	379231.29	63343.43	315887.86

Separation task		p/MPa	R	ξ_LK	ξ_HK	V/(kmol/h)	T_D/K	T_B/K	Q_c/(GJ/h)	Q_r/(GJ/h)
1	ABCD\|BCDE	1.00	0.66	0.980	0.020	276.54	331.76	375.59	4.591	5.026
2	A\|BCD	0.82	2.33	0.980	0.020	148.57	293.69	—	2.242	—
3	BCD\|CDE	0.82	1.25	0.980	0.020	498.86	341.94	380.63	6.155	9.686
4	B\|CD	0.61	6.96	0.980	0.020	1081.12	319.10	342.73	19.070	10.909
5	CD\|DE	0.61	4.32	0.999	0.020	477.92	—	374.03	—	9.910
6	C\|D	1.00	1.33	0.980	0.020	522.23	353.86	—	8.782	—
7	D\|E	1.00	13.97	0.980	0.020	2000.57	391.05	405.00	26.789	36.626
{IHE}：{1, 1, 1}：2-3 (1)、4-5 (1)、6-7 (1) TAC：4924023.13 USD/a
年度设备费：827841.36 USD/a；年度操作费：4096181.78 USD/a
中间组分回收率：ABCD\|BCDE：ξ_B = 0.3668、ξ_C = 0.2490、ξ_D = 0.0507；BCD\|CDE：ξ_C = 0.6582、ξ_D = 0.1055；CD\|DE：ξ_D = 0.1547 能量匹配：8.782 GJ/h (6→4), 5.026 GJ/h (7→1), 9.686 GJ/h (7→3) , 9.910 GJ/h (7→5) , 2.127 GJ/h (7→4)