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Aleksandar Anastasovski*
Ss Cyril and Methodius University
Faculty of Technology and Metallurgy, Skopje, Macedonia
email: AleksandarA@t-home.mk
Vera Meško
Ss Cyril and Methodius University
Faculty of Technology and Metallurgy, Skopje, Macedonia
email: ameshko@t-home.mk
Predrag Rašković
University of Nis
Faculty of Technology, Leskovac, Serbia
email: pr.raskovic@sezampro.yu
Liljana Markovska
Ss Cyril and Methodius University
Faculty of Technology and Metallurgy, Skopje, Macedonia
email: markovska@tmf.ukim.edu.mk
ABSTRACT
This paper reports a simulation analysis of energy consumption in steam distillation units,
which are used as a part of manufacture in the factory for yeast and alcohol production.
Distillation units are stored in the final stage of alcohol manufacture route following the
anaerobic fermentation processes. The main products of distillation process are: 96% Vol.
ethyl alcohol and technical alcohol, which presents the mixture of ethanol, aldehydes and
some other less volatile components than ethanol. Distillery is consisting of columns in
series. First of them is distillation column, but other are rectification columns. Their work
parameters are determined by inlet feed composition. When composition is not changing a
lot, whole distillation system is close to steady state. Flow, temperature and pressure are
parameters for monitoring.
The simulation analysis has been made by simulation software Aspentech HYSYS. The
validity of the model in terms of mass flow rate, temperature and pressure was examined
using actual plant data at steady-state conditions. Comparison between model results and
plant data shows good consistency and enabled the retrofit design with improved efficiency
of the unit.
1. INTRODUCTION
Last few decades increase software using for simulation of production facilities with
improving their work [1]. There are many types of software that are in use these days. Some
of them are specialized for some specific processes in chemical technology, but some of them
*
Corresponding author: Aleksandar Anastasovski, e-mail: AleksandarA@t-home.mk
have wide field of possibilities. Using of simulation software becomes very useful in many
critical areas. Software can predict some problems that could become, finding solutions for
any case, upgrading of present process with choosing the right project proposed solution,
predict of process dynamics in case of inlet disturbance and many other features. So,
simulation software become great solution in process complexity, such as uncertainly,
dynamic behaviour and its feedback. There are developed algorithms which could be used for
exploring and optimizing the real process with this kind of software [2].
Great parts of component that have temperature of evaporation lower then ethanol are
separated in second column. All of them are contained in top outlet stream (10) in column
DC-101. The main components of that stream are acetaldehyde and ethanol. Ethanol is
present because of component molecules interaction. Condensate of first heat exchanger is
consisting partially of heavy components. It return back to the column and is known as reflux
(11). All other condensates (18) are collected in tank for technical alcohol storage. Bottom
outlet stream from column DC-101 (13) is feeding stream for column DC-102. Column DC-
101 is positioned higher then column DC-102, so there is not need pump for enforces the
flow. That stream contains different kind of alcohols and organic acids present in alcoholic
wort. Their separation is the aim of third rectification column DC-102.
Heavy components like water and acetic acid from column DC-102 are separated and
transported with outlet stream from the bottom of the column named “Luter” (21). It has the
highest operating temperature and pressure in this column. Separated components are more
evaporative than ethanol at the top of column. That stream (16) is going to technical alcohol
storage tank. Better purification of ethanol depends by fusel oil separation as well as
separation of other present impurities. Fusel oils (32) are mixture of higher alcohols. They are
taken from trays where its concentration is highest. This alcohol mixture has specific
properties when this mixture is dissolved in water at appropriate concentration. In that case,
layer of non soluble components are formed on the top. So, decanting is appropriate method
for its separation. Decanted stream (34) takes them and transport to place for them. Soluble
part (35, 50, and 51) is going back to the column DC-102. Potable alcohol (19) is taken from
the tray with little bit lower temperature then temperature of ethanol boiling. In that tray
concentration of ethanol is maximal, because it is azeotropic mixture ethanol – water (96%
vol. ethanol). That stream is cooled and transported to the potable alcohol storage tank.
3. MODEL DEVELOPMENT ON ASPEN HYSYS PLATFORM
ASPENTECH HYSYS software is CAD/CAM type of software. It interactively changes
whole simulated system in case to change some of inputted parameters. Simulation method is
consisting of few steps. That is described in further text for distillation system simulation
model development. Hyprotech (Aspentech now) is a leader in the area of process simulation.
This technology is possible to have tremendous impact on not only the way that engineers
approach control strategy development, but on how we approach modelling in general [5].
Figure 2. The first column with its cooling system, part of distillation system
Heat exchangers – (Figure 2) are determined with inlet and outlet streams, temperatures,
pressures and flows of those streams, heat exchanger type, number of tubes, diameter, tube`s
position, shell diameter, pipe connection in fluid flow spaces, material of construction,
fouling factor, horizontal or vertical position of HE (all that for tube and shell type of heat
exchanger), pressure drop in shell side and tube side. These are parameters that specify all
heat exchangers in this system. There are three heat exchangers in series specified for the first
column that are cooling top outlet stream. Cooling fluid for the first heat exchanger is
alcoholic wort as the main feed of the system. Cooling water with specific characteristics is
used for cooling in other two heat exchangers. These heat exchangers are positioned
vertically and have duty to cool the top outlet stream as well as phase separation. Simulation
model need phase separation. There is added phase separator to every heat exchanger outlet.
So, phase separators separate gases and send them to the other following heat exchanger of
the series. All liquid phases, separated after heat exchangers are sent to mixer with aim to
form new stream that will feed second column. Mixer is specified to take the lowest pressure
of streams (atmospheric pressure). Phase separators are specified to separated phases in
conditions that they leave heat exchangers. All heat exchangers are positioned on higher level
of columns, so streams not need pumps, but in simulation model pump must be added to
simulate that pressure by higher level position. The last heat exchanger in series needs to
have outlet to the atmosphere, where separated CO2 and air is going. That gases are coming
from alcoholic wort, where are formed in process of fermentation. They are separated in
correct operation of distillery.
Mixing of three streams with different temperatures provoke small evaporation. That is
simulated with phase separator, where (47) is stream of evaporation. Quantities are very
small.
Distillation column 1 (DC-100) – (Figure 2) the basic specifications that are need for column
specification are: number of trays, high and diameter of trays, high of tray`s overflow, type of
trays, temperature and pressure on the top and on the bottom of column, feeding stream inlet
tray, specified trays for outlet streams, as well as the tray of steam inlet. This is case with
directly injection of steam in column, so pressure and temperature of steam are very
important. Quantity of steam that is need for column is interactively determined. Tray
efficiency coefficient is needed to be input. It is used to be determined by the results of
simulation. Physical and chemical characteristics of outlet streams (6) and (5) are simulation
values. Those values are used in further simulation of process.
Distillation column 2 (DC-101) – This column (Figure 3) need all specifications given for
determination of the first column in series, but also need some new specifications. This
column has reflux, so that kind of equipment is chosen. The first heat exchanger is contained
into the column as one equipment unit. That means simulation of two heat exchangers in
series. Reflux ratio is important specification for this column.
Figure 3. The second and third columns in series, part of distillation system
Distillation column 3 (DC-102) – This is the most complicated part of simulation of this
system (Figure 3). There are few inlet, outlet and recycled streams. Basically, this column is
determined as other two, but there are added new specifications such as outlet and inlet
stream`s tray number, reflux ratio and flows of outlet streams. Number of specifications is
equal to number of freedom degree of the column. That must satisfy to be zero degree. One
of streams is going out to be purified. After its purification the pure components are going
back to the column. That is (32) stream. It is solving with water (33) in online mixer for two
streams. Component splitter X-100 is used for decanting simulation. Component splitter is
specified to split defined components and with determined efficiency. One outlet stream is
going to drainage with fusel oils (34); other (50) is going back to the column DC-102.
Recycling stream is simulating with logic connectors. That kind is connector for recycling
RCY-1 (Figure 3). There are specified returning conditions of stream, such as temperature,
pressure and flow.
Potable alcohol stream, technical alcohol stream and fusel oils coolers are determined as all
other heat exchangers. Cooling water is used as cooling medium.
There are also made comparation of steam and cooling needs for changing of flow. This
simulation model is used for this comparation and simulated situation of variables is used as
referent values presented as 100% (100% of variable value). This comparation is made to be
determined the optimal energy need for this plant. The main preferences are:
- Column temperature and pressure profile is not changing
- Steam and cooling fluid characteristics are the same
- Ethanol concentrations are the same in every part of plant
- Feeding fluid, steam mass flow and energy taken from coolers are changed
The basic idea of this analysis is determination of optimal work of distillation plant.
4. RESULTS AND DISCUSSION
Results that are calculated with software and the values of real distillation system are
compared. Error analysis is done. Deviations are represented in Table 1. According to
represented data, values of simulated parameters and parameters in real system are evidently
close. This prepared simulation model of distillery could be used for further estimation of
system. That means estimation of energy that would be needed for any change in distillery
operating and estimation of equipment before doing correction in some part of system.
Alcoholic wort composition deviation could be one of disturbances of the system. Changing
of alcoholic wort composition could be happened as a result of fermentation problems.
This model could be also used for upgrade of present system with new equipment and its
design and efficiency estimation.
Table 1. Deviation between simulated and real values of distillery system parameters (error analysis)
Stream Pressure deviation (%) Temperature deviation (%) Flow deviation (%)
4 2,000 0,310 2,315
14 1,960 1,163 26,666
15 4,761 0,661 7,894
5 10,775 0,588 0,689
1 0,542 0,000 0,184
2 0,732 0,000 0,184
6 2,316 0,795 20,463
7 2,316 13,841 11,583
9 4,735 4,666 11,196
10 2,316 1,273 13,647
11 2,316 7,246 8,080
16 2,316 0,000 6,944
17 2,316 0,000 13,157
18 2,316 1,550 24,000
19 0,886 7,977 31,654
20 0,886 0,000 31,654
21 4,166 0,582 36,398
13 13,846 5,654 24,769
With this analysis, we approved the simulation model. So, we can try theoretically to determine
optimal working state of plant. There are rewieved 5 cases. Case no. 3 is simulation model. Other
cases are simulation of 50%, 75%, 125% and 150% of feeding flow value in case No.3. So, values of
steam in every column, as well as total steam needed for every case are relative value of steam needs
in case No.3. The same is used for cooling needs. The results are shown in table 2 and 3. The
graphical presentation of results are given on Figures 4, 5, 6 and 7.
Table 2. Simulation results for every column separately
Case % of % of % of % of % of % of % of % of
feed flow steam cooling steam steam cooling Technical Potable Alc.
needs (DC-100) needs needs (DC-101, Alc.flow flow
(DC-100) (DC- (DC- DC-102)
101) 102)
1 150 152 168,67 200,00 136,73 142,76 155,17 150
2 125 127 142,79 166,67 114,29 119,16 130,20 125
3 100 100 100,00 100,00 100,00 100,00 100,00 100
4 75 75 75,21 93,33 67,35 69,78 74,73 75
5 50 50 50,15 73,33 44,90 47,45 50,54 50
Table 3. Total steam and cooling need of distillation plant determined with simulation
Figure 4. Presentation of percentage of feeding Figure 5. Comparation of total steam and total
flow, steam and cooling needs for every case cooling per unit of produced potable alcohol
compared with case No. 3
Figure 6. Funcion of total steam needs per Figure 7. Funcion of total cooling needs per
product per case (better minimum product per case (better minimum
determination) determination)
Results shown on table 4 are expected and proportional to feeding flow. Otherwise, total results and
especially total steam and total cooling per product give us good data for optimization. In comparation
of all cases, case No. 4 needs minimum energy and cooling. That is optimal case of plant working.
The values are close, so there are 3% lower steam needs and 6% lower cooling needs.
CONCLUSION
Preparing of simulation model for some production plant could predict way of plant working.
Theoretically could be predicted optimal needs of energy. The next step of this theoretically
prediction is practically aprovement.
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fermentation plant” , ECOS 2008 – Krakow, Poland
5. Mahoney, Donald P., Fruehauf, Paul S., “An Integrated approach for distillation
column control design using steady state and dynamic simulation” (2009) URL:
http://www.aspentech.com/publication_files/An_Integrated_Approach_for_Distillatio
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