Distillation column Design

1. Enthalpy, ∆H (kJ/h)
[HYSYS]
Enthalpy. ∆H (kJ/s) [HYSYS] Total Enthalpy (kW)
E-101 2 → 3 Cold, C1 -103.00 -58.40 44.60 5.6686 910149.3767 252.8193
E-103 11 → 12 Cold, C2 41.50 80.00 38.50 12.4022 1718939.9793 477.4833
E-104 15 → 16 Cold, C3 -253.00 150.00 403.00 0.4379 635245.9502 176.4572
E-102 7 → 8 Hot, H1 150.00 50.00 100.00 5.6144 2021179.1707 561.4387
E-105 18 → 19 Hot, H2 159.00 50.00 109.00 7.6944 3019301.1578 838.6948
E-108 20 → 21 Hot, H3 60.30 10.00 50.30 0.8485 153652.7240 42.6813
E-109 22 → 23 Hot, H4 106.00 30.00 76.00 2.6086 713713.3865 198.2537
∆Tmin (℃) 10.00 ∆Tmin/2 (℃) 5.00
Stream Name Stream Type Supply Temperature, TS(℃)
Target
Temperature,
TT(℃)
Heat Capacity Flowrate, CP
(kW/℃)
Supply Temperature, TS(℃) Target Temperature, TT(℃) ∆Tmin/2 (℃)
2 → 3 Cold, C1 -103.00 -58.40 5.6686 -98.00 -53.40 5.00
11 → 12 Cold, C2 41.50 80.00 12.4022 46.50 85.00 5.00
15 → 16 Cold, C3 -253.00 150.00 0.4379 -248.00 155.00 5.00
7 → 8 Hot, H1 150.00 50.00 5.6144 145.00 45.00 5.00
18 → 19 Hot, H2 159.00 50.00 7.6944 154.00 45.00 5.00
20 → 21 Hot, H3 60.30 10.00 0.8485 55.30 5.00 5.00
22 → 23 Hot, H4 106.00 30.00 2.6086 101.00 25.00 5.00
First Trial Second Trial
1 155.00 0 0.4379
1.00 0.4379 0.4379 Deficit
2 154.00 C3 -0.4379 0.0000
9.00 -7.2566 -65.3093 Surplus
3 145.00 C3-H2 64.8714 65.3093
44.00 -12.8710 -566.3229 Surplus
4 101.00 C3-H1-H2 631.1943 631.6322
16.00 -15.4796 -247.6732 Surplus
5 85.00 C3-H1-H2-H4 878.8676 879.3054
29.70 -3.0774 -91.3991 Surplus
6 55.30 C2+C3-H1-H2-H4 970.2667 970.7046
8.80 -3.9259 -34.5483 Surplus
7 46.50 C2+C3-H1-H2-H3-H4 1004.8150 1005.2529
1.50 -16.3281 -24.4922 Surplus
8 45.00 C3-H1-H2-H3-H4 1029.3072 1029.7451
20.00 -3.0193 -60.3856 Surplus
9 25.00 C3-H4-H3 1089.6927 1090.1306
20.00 -0.4107 -8.2135 Surplus
10 5.00 C3-H3 1097.9063 1098.3441
58.40 0.4379 25.5710 Deficit
11 -53.40 C3 1072.3353 1072.7732
44.60 6.1065 272.3478 Deficit
12 -98.00 C1+C3 799.9875 800.4254
150.00 0.4379 65.6789 Deficit
13 -248.00 C3 734.3086 734.7465
Minimum Hot Utility, ∆Qh,min 0.4379
Minimum Cold Utility, ∆Qc,min 734.7465
Pinch Temperature, Tpinch 154.00
Hot Pinch Temperature, Tpinch hot 159.00
Cold Pinch Temperature, Tpinch cold 149.00
906.3219
906.3219
0.00
Stream Requires Temperature Reduction / Increment
Heat Exchanger Stream Name Stream Type
Supply
Temperature,
TS(℃)
Target Temperature, TT(℃)
Temperature Difference,
∆T(℃)
Heat Capacity Flowrate, CP (kJ/s.℃)
(kW/℃) [ Formula:
CP = ∆H / ∆T ]
Based on HE requirement
Temperature, T (℃) Stream Data Population
Temperature Difference, ∆T
(℃)
Total Cold CP - Total Hot CP,
∑CPC-∑CPH (kW/℃)
Enthalpy Difference, ∆H (kW)
[Formula: ∆H = ∆T*(∑CPC-∑CPH)]
Deficit / Surplus
906.7598
1641.0685
Cold and Hot Stream Shifted Temperature
Temperature Interval Constructed Based on Shifted Temperature
Temperature Interval Heat Balance Heat Cascade
Utility (kW)
∆Hh - Qc,min
∆Hc - Qh,min
% Difference
Utility, Q (kW)
Pinch Temperature (℃)
Heat Recovery, Qrec (kW)
Hot Stream Shifted Temperature, ℃ T∗
= T −
T
2
Cold Stream Shifted Temperature, ℃ T∗
= T +
T
2
C1
C3
C2
H1
H2
H3
H4

2. 216.1544 261.3303
CPh ≥ CPc √√ CPh ≥ CPc √√ CPh ≥ CPc √√ CPh ≥ CPc XX CPh ≥ CPc XX CPh ≥ CPc XX
Nh ≥ Nc √√ Nh ≥ Nc √√ Nh ≥ Nc √√ Nh ≥ Nc √√ Nh ≥ Nc √√ Nh ≥ Nc √√
Th > Tc XX Th > Tc √√ Th > Tc √√ Th > Tc √√ Th > Tc √√ Th > Tc √√
∆T ≥ 10℃ √√ ∆T ≥ 10℃ √√ ∆T ≥ 10℃ √√ ∆T ≥ 10℃ √√ ∆T ≥ 10℃ √√ ∆T ≥ 10℃ √√
∆H:H2 (kW) 577.3645 ∆H:H2 (kW) 838.6948 ∆H:H2 (kW) 324.5452 ∆H:H1 (kW) 561.4387 ∆H:H1 (kW) 561.4387
∆H:C1 (kW) 252.8193 ∆H:C3 (kW) 0.0000 ∆H:C2 (kW) 477.4833 ∆H:C2 (kW) 152.9381 ∆H:C2 (kW) 477.4833
Balance ∆H (kW) 324.5452 Balance ∆H (kW) 838.6948 Balance ∆H (kW) 152.9381 Balance ∆H (kW) 408.5005 Balance ∆H (kW) 83.9553
∆H (kW) [C1] 252.8193 ∆H (kW) [C3] 0.0000 ∆H (kW) [H2] 324.5452 ∆H (kW) [C2] 152.9381 ∆H (kW) [C2] 477.4833
CP (kW/℃) [H2] 7.6944 CP (kW/℃) [H2] 7.6944 CP (kW/℃) [C2] 12.4022 CP (kW/℃) [H1] 5.6144 CP (kW/℃) [H1] 5.6144
Temp Supply, Ts (℃) 125.04 Temp Supply, Ts (℃) 159.00 Temp Target, Tt (℃) 80.00 Temp Target, Tt (℃) 150.00 Temp Target, Tt (℃) 150.00
Temp Intermediate T4* (℃) Temp Intermediate T1* (℃) Temp Intermediate T3* (℃) Temp Intermediate T4* (℃) Temp Intermediate T3* (℃)
CPh ≥ CPc √√ CPh ≥ CPc √√ CPh ≥ CPc √√ CPh ≥ CPc √√
Nh ≥ Nc √√ Nh ≥ Nc √√ Nh ≥ Nc √√ Nh ≥ Nc √√
Th > Tc XX Th > Tc √√ Th > Tc √√ Th > Tc √√
∆T ≥ 10℃ √√ ∆T ≥ 10℃ √√ ∆T ≥ 10℃ √√ ∆T ≥ 10℃ √√
∆H:H4 (kW) 198.2537 ∆H:H1 (kW) 561.4387 ∆H:H2 (kW) 838.6948 ∆H:H1 (kW) 561.4387
∆H:C3 (kW) 0.0000 ∆H:C3 (kW) 176.0193 ∆H:C2 (kW) 261.3303 ∆H:C2 (kW) 216.1544
Balance ∆H (kW) 198.2537 Balance ∆H (kW) 385.4193 Balance ∆H (kW) 577.3645 Balance ∆H (kW) 345.2843
∆H (kW) [C3] 0.0000 ∆H (kW) [C3] 176.0193 ∆H (kW) [C2] 261.3303 ∆H (kW) [C2] 216.1544
CP (kW/℃) [H4] 2.6086 CP (kW/℃) [H1] 5.6144 CP (kW/℃) [H2] 7.6944 CP (kW/℃) [H1] 5.6144
Temp Supply, Ts (℃) 106.00 Temp Supply, Ts (℃) 150.00 Temp Supply, Tt (℃) 159.00 Temp Target, Tt (℃) 150.00
Temp Intermediate T1* (℃) Temp Intermediate T1* (℃) Temp Intermediate T3* (℃) Temp Intermediate T3* (℃)
HEAT EXCHANGER NETWORK (HEN)
FEASIBILITY STUDY (BELOW PINCH)
Stream: C3 → H3 [HE3] Stream: H2 → C1 [HE1] Stream: H2 → C3 Stream: C2 → H2 Stream: C2 → H1 [HE3] Stream: C2 → H1
T4* T1* T3* T4* T3*
[ Formula: ∆H = CP*∆T ] [ Formula: ∆H = CP*∆T ] [ Formula: ∆H = CP*∆T ] [ Formula: ∆H = CP*∆T ] [ Formula: ∆H = CP*∆T ]
(Choose the lowest ∆H value between the two stream) (Choose the lowest ∆H value between the two stream) (Choose the lowest ∆H value between the two stream) (Choose the lowest ∆H value between the two stream) (Choose the lowest ∆H value between the two stream)
(Choose the stream with balance ∆H) (Choose the stream with balance ∆H) (Choose the stream with balance ∆H) (Choose the stream with balance ∆H) (Choose the stream with balance ∆H)
92.18 159.00 53.83 122.76 64.95
[HE1] Stream: H4 → C3 [HE1] Stream: C3 → H1 [HE2] Stream: H2→ C2 [S2] [HE4] Stream: C2 [S1] → H1
[ Formula: ∆H = CP*∆T ] [ Formula: ∆H = CP*∆T ] [ Formula: ∆H = CP*∆T ] [ Formula: ∆H = CP*∆T ]
(Choose the lowest ∆H value between the two stream) (Choose the lowest ∆H value between the two stream) (Choose the lowest ∆H value between the two stream) (Choose the lowest ∆H value between the two stream)
T1* T1* T3* T3*
(Choose the stream with balance ∆H) (Choose the stream with balance ∆H) (Choose the stream with balance ∆H) (Choose the stream with balance ∆H)
106.00 118.65 125.04 111.50
CPh ≥ CPc , Nh ≥ Nc
CPh ≤ CPc , Nh ≤ Nc
150℃
60.3℃
10℃
-253℃
-58.4℃
102.16℃
T3*=69.30℃
-103℃
𝐓𝟏∗
= 𝐓𝐒 −
∆𝐇
𝐂𝐏
149℃
159℃
T1* = 136.12℃
-253℃
𝐓𝟏∗
= 𝐓𝐒 −
∆𝐇
𝐂𝐏
80℃
103.21℃
50℃
T3*
𝐓𝟏∗
= 𝐓𝐒 −
∆𝐇
𝐂𝐏
46.99℃
150℃
T4*
41.5℃
𝐓𝟏∗
= 𝐓𝐒 −
∆𝐇
𝐂𝐏
80℃
150℃
T3*
41.5℃
𝐓𝟏∗
= 𝐓𝐒 −
∆𝐇
𝐂𝐏
5.6144
6.7878
216.1544 kW
261.3303 kW
80℃
150℃
T4* = 111.5℃
41.5℃
𝐓𝟏∗
= 𝐓𝐒 −
∆𝐇
𝐂𝐏
80℃
150℃
T2* = 102.16℃
41.5℃
𝐓𝟏∗
= 𝐓𝐒 −
∆𝐇
𝐂𝐏
H1: 150℃
H2: 159℃
H3: 60.3℃
H4: 106℃
C1: -103℃
C3: -253℃
C2: 41.5℃
H1: 50℃
H2: 50℃
H3: 10℃
H4: 30℃
C1: -58.4℃
C2: 80℃
C3: 150℃
159℃
149℃
BELOW PINCH
ABOVE PINCH
5.6686
0.4379
12.4022
5.6144
7.6944
0.8485
2.6086
CP (kW/℃)
252.8193
176.4572
477.4833
561.4387
838.6948
42.6813
198.2537
∆H (kW)
0 kW
662.2376 kW
0 kW
409.4183 kW
83.9553 kW
HE1
T1* = 136.07℃
176.4572 kW
HE2
T2* = 103.21℃
252.8193 kW
HE3
T3* = 64.95℃
477.4833 kW
83.9553 kW
C
42.6813 kW
C
198.2537 kW
C
0 kW
409.4183 kW
C
0.4379 kW
H
149℃
150℃
T1*
-253℃
𝐓𝟏∗
= 𝐓𝐒 −
∆𝐇
𝐂𝐏
149℃
106℃
T1*
-253℃
𝐓𝟏∗
= 𝐓𝐒 −
∆𝐇
𝐂𝐏

3. H1 561.4387 Total Hot
H2 838.6948 1641.0685
H3 42.6813
H4 198.2537
C1 252.8193 Total Cold
C2 [S1] 261.3294 906.7598
C2 [S2] 216.1539
C3 176.4572 Qc,min
734.3086
Type of utility
Before
integration
After integration Heat Recovery Percentage saving (%)
Hot utility 906.7598 0.4379 906.3219 99.95
Cold utility 1641.0685 734.7465 906.3219 55.23
Total 2547.8283 735.1844 1812.6438 71.14
Cost of
Utilities
Before integration Cost of Utilities After integration Cost of Utilities
(RM/kW.h) (kW) (RM) (kW) (RM)
LP Steam 0.2195 906.7598 RM1,576,471.03 0.4379 RM761.32
Cooling Water 0.0055 1641.0685 RM71,886.51 734.7465 RM32,185.35
Total 0.2250 2547.8283 RM1,648,357.54 735.1844 RM32,946.67
Cost of
Utilities
Cost of Utilities Cost of Utilities
PERCENTAGE COST UTILITY SAVED
($/GJ) (RM/kJ) (RM/kW.h) 98.00
LP Steam 14.05 0.000060977 0.2195
Cooling Water 0.354 0.000001536 0.0055
1 USD 4.34 RM
1 day 24 hour
1 hour 60 min
1 min 60 s
1 GJ 1000000 kJ
Utilities Shifted Temp
0.4379 155.00 MP
0.0000 154.00
65.3093 145.00
631.6322 101.00
879.3054 85.00
970.7046 55.30
1005.2529 46.50
1029.7451 45.00 CW
1090.1306 25.00
1098.3441 5.00 R
1072.7732 -53.40 R
800.4254 -98.00
734.7465 -248.00 338.0266
Type of utility
Heat Requirement of Heat and Cold Utilities Before and After Heat Integration
Type of utility
216.1544
261.3303
0 kW
0 kW
C2: 41.5℃
5.6144
6.7878
H1: 150℃
H2: 159℃
H4: 106℃
H3: 60.3℃
C1: -103℃
C3: -253℃
H1: 50℃
H2: 50℃
H3: 10℃
H4: 30℃
C2: 80℃
C3: 150℃
C1: -58.4℃
159℃
149℃
BELOW PINCH
ABOVE PINCH
5.6686
0.4379
5.6144
7.6944
0.8485
2.6086
CP (kW/℃)
252.8193
176.0358
561.4387
838.6948
42.6813
198.2537
∆H (kW)
0 kW
401.3287 kW
662.6590 kW
345.2843 kW
0.4379 kW
H
HE1
176.0358 kW
T1* = 136.12℃
0 kW
216.1544 kW
T4* = 111.50℃
HE4
148.5094 kW
198.2537 kW
C
42.6813 kW
C
148.5094 kW
C
345.2843 kW
C
HE2
261.3303 kW
T2* = 102.16℃
HE3
252.8193 kW
T3* = 69.30℃
152.00
154.00
156.00
158.00
160.00
162.00
0 1 2 3 4 5 6 7 8 9 10
Cascade Heat Flow, ∆H (kW)
Grand Composite Curve (GCC)
-300
-250
-200
-150
-100
-50
0
50
100
150
200
0 200 400 600 800 1000
Shifter
Temperature,
T*
(℃)
Cascade Heat Flow, ∆H (kW)
Grand Composite Curve (GCC)