Optimizing Desiobutainizer Operation with EPCON CHEMPRO Simulation

Goals and Challenges

• Goal:To optimize the operation of a Desiobutainizer in a refining or chemical plant to maximize efficiency, reduce energy consumption, and ensure the production of high-quality butane products.
• Challenges:Desiobutainizers are critical units in refining processes, used to separate butane from other hydrocarbons. Achieving the desired separation requires careful control of operating temperatures, pressure, and flow rates. The challenge lies in optimizing these variables to minimize energy usage while maintaining product purity.

Desiobutainizer Process Overview

The Desiobutainizer is a distillation column that separates butane (C4) from other hydrocarbons, typically using a distillation process that relies on differences in boiling points. The process can be complex due to the presence of multiple components and close boiling points, which can cause separation difficulties.

EPCON CHEMPRO Simulation in Process Design and Optimization

• Process Flow Simulation (PFS):Using EPCON CHEMPRO, engineers simulate the desiobutainizer column, including all unit operations involved, such as heat exchangers, compressors, and splitters. This simulation creates an optimized process flow diagram (PFD) to predict system performance under various operating conditions. The PFS allows for real-time analysis of potential configurations and helps visualize how changes in feed composition, pressure, and temperature can affect separation efficiency.
• Column Performance Optimization:In EPCON CHEMPRO, the Desiobutainizer can be simulated with different operational parameters such as column stage number, feed stage location, and reboiler duty. By adjusting these parameters, engineers can determine the ideal conditions for maximum separation efficiency while maintaining a balanced energy requirement.
• Energy and Pressure Drop Analysis:The tool enables detailed analysis of the pressure drops and heat transfer across the desiobutainizer column. This information is critical for evaluating energy efficiency and ensuring that the column operates within optimal limits to minimize operational costs.
• Property Package Customization:Using EPCON CHEMPRO's property package capabilities, engineers can specify the accurate physical properties of the feed components (e.g., butanes, propane, methane) based on real-time data. The property packages in CHEMPRO support industry-recommended methods for hydrocarbon systems, ensuring precise thermodynamic modeling and accurate simulation of the separation process.
• Pinch Analysis for Heat Integration:The Pinch Analysis tool within EPCON CHEMPRO allows engineers to optimize the heat integration of the Desiobutainizer system, reducing the energy consumption associated with heating and cooling streams. By assessing the heat exchanger network, the simulation can identify opportunities for energy recovery and waste heat utilization, leading to significant cost savings.

Facility and Operational Impact

• Optimized Separation Efficiency: The simulation results from EPCON CHEMPRO show that adjusting the feed location and optimizing reboiler temperatures can significantly improve the purity of the butane product while minimizing impurities like propane and methane. This results in a higher-quality output product for downstream processing.
• Energy Savings:By optimizing operating conditions such as pressure and column internals, the simulation predicts an energy savings of up to 15% over traditional operating methods. The Pinch Analysis also identifies key areas for heat recovery, contributing further to operational efficiency.
• Reduced Operating Costs: The ability to simulate various configurations and operational conditions in EPCON CHEMPRO helps engineers identify the most cost-effective setup for the Desiobutainizer. This reduces the need for trial and error in the field, minimizing downtime and operational costs. The advanced optimization also reduces the consumption of utilities like steam and electricity, leading to long-term savings.
• Enhanced Reliability and Performance:With EPCON CHEMPRO, engineers can test different failure scenarios and analyze how the Desiobutainizer responds to changes in feed composition or operating conditions. This improves the reliability of the unit and ensures that the plant can continue to operate smoothly even under fluctuating feed conditions.

Conclusion

By leveraging the advanced simulation capabilities of EPCON CHEMPRO, engineers successfully optimized the Desiobutainizer process, resulting in higher product quality, lower energy consumption, and significant cost savings. The Process Flow Simulation and Pinch Analysis tools allowed for the identification of optimal operational conditions and energy-efficient strategies. This case demonstrates how EPCON CHEMPRO can be an essential tool for designing, simulating, and optimizing complex chemical processes to meet modern industry demands, reduce emissions, and improve profitability.