1

Summary.
The objective of the report is to simulate the DC with heat integration. The component for this
experiment is methanol and water and it is equimolar mixture at 2700kmol/h at 25C and 5.2bar.
Select SRK as a fluid package and use SI unit for this simulation. After that, insert all the
equipment and data. To do heat integrated method we use adjust tool to adjust the split ratio in
splitter until the heat duties of the condenser of DC1 matches second reboiler of DC2. Then
attach the energy stream from the first condenser (DC1) to the second reboiler (DC2).
















2

Introduction.
The production of methanol is carried out in a moderate pressure synthesis loop by direct
hydrogenation of carbon dioxide, which generates a liquid product that contains a binary mixture
of methanol that is nearly free of water, dehydration is achieved commonly by distillation, a
process in which energy is invested in return Ior separation. To reduce the sizable energy cost,
heat integrated conIiguration are considered commonly as alternatives to a single distillation
column with total condenser. The simulation considered an equimolar mixture at 2700 kmol/h at
25C and 5.2 bar. It is then split and fed to two distillation columns, one at reduced pressure, with
the design specifications shown in the following table.
DC1 DC2
Pressure (bar) 5.2 1.01
No of trays 16 13
Feed trays 12 9
Estimated reflux ratio 1.26 0.834
X
D
(mole fraction) of methanol 0.96 0.96
X
B
(mole fraction) of methanol 0.04 0.04

Hints:
1. Use SRK as a fluid package.
2. Use SI unit for this simulation
3. Use the split ratio of 50-50 for splitter.
4. Use total condenser for both DCs.
5. For heat integration exercise:
a) Use adjust tool and adjust the split ratio in splitter until the heat duties of the
condenser of DC1 matches second reboiler of DC2
b) Then, attach the energy stream from the first condenser(DC1) to the second
reboiler(DC2)

3

Distillation operations are responsible for 40% of the energy used in the chemical process
industries. The technology that can reduce this energy requirement significantly will represent a
major breakthrough in energy efficiency and give significant competitive edge to the companies
that adopt it. Heat integrated distillation column are such technology. By combining rectifying
and stripping column in an annular arrangement so that the exchange heat along their length and
elevating pressure in the rectifying section, energy saving of nearly 50% can be achieve.

















4

Objective.
1. To simulate the distillation column with heat integration.
2. To determine how to reduce pressure in DC2
3. To determine reflux ratio at DC1 and DC2
4. To determine the value of the split ratio of the feed stream for each DC after heat
integration.
5. To determine the duty of the condenser of DC1 and the reboiler of DC2 before
integration of heat.
6. To determine the mole fraction of the bottom product in DC2 before and after integrating
the heat.














5

Theory.
Distillation is a method of separation of substances based on differences in their volatilities. In
simple distillation, all the hot vapors produced are immediately channeled into a condenser
which cools and condenses the vapors. Thus, the distillate will not be pure - its composition will
be identical to the composition of the vapors at the given temperature and pressure, and can be
computed from Raoult's law.
Multicomponent distillation systems employ multiple column units for multiple individual
separation tasks. The final performance of a multicomponent distillation system will depend on
the optimum synergy of the multiple individual tasks within the distillation system. Traditionally,
there are two techniques to reduce energy consumption of a multicomponent distillation system.
One is through heat integrations among the condensers and reboiler of the traditional simple
column configurations. Another is using thermal couplings to eliminate some of the condensers
and reboiler of traditional distillation configurations. These two techniques are separately used in
design of distillation systems for ternary mixtures.
In this experiment we use heat integrated in distillation column. Although the heat integrated in
distillation column concept has been researched for a number of years, it has not yet been
commercialized. Recent literature describes an embodiment of the concept, which resembles a
shell-and-tube heat exchanger. However an alternative embodiment based on a compact (plate)
heat exchanger has several potential advantages over the shell-and-tube design. These
advantages include compactness, a closer temperature approach, modular structure, and
flexibility in design.
In order to investigate the feasibility of a heat integrated in distillation column design based on a
plate-fin heat exchanger, a computer program has been developed. This approach is based on an
existing model for conventional distillation, coupled to a spreadsheet program that incorporates
correlations for such factors as flooding, wetting, and fin efficiency, and that takes account of
geometric constraints in the plate-fin design. The software was applied in a preliminary case
study for a propane-propene splitter. This confirmed the scope for energy savings, with energy
savings of about 37% compared to a vapour-recompression column. First indications suggest that
the economics may also be favourable. It was concluded that the plate-fin design is feasible in
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principle. However the required hydraulic diameter was larger than currently available in
commercial plate-fin heat exchangers.
In this experiment, the stream 1 containing methanol and water was in equimolar condition in
which each component consists of 0.5 mole fraction. Then after the heat integration by using
adjusting the split ratio on both stream to DCs we find that to level up the energy that been
discharged from condenser DC 1 with the energy needed in the reboiler DC 2, we have to split
the stream into 0.4607 to DC1 and 0.5930 to DC 2.
















7

Procedure.

1. Open a new case and select all the component involve. They are methanol and water.


2. Then, select SRK as a fluid package.

8


3. Enter the simulation and pick up one stream. Fill up all the data that needed.


4. For this experiment, the compound is equimolar mixture. That mean the composition is
0.5 for water and methanol.


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5. Pick up TEE-100 equipment and distillation column.

6. Set all the data for TEE-100.



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7. Then fill the parameter for outlet1 and outlet2. For both is 0.5 because it is equilmolar
mixture.


8. Double click at distillation column and set all the data. Set the condenser to partial
condenser.

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9. After all data was filled click next.

10. For reboiler configuration, nothing to be done and continue by clicking the next button.

12


11. Set the condenser pressure and reboiler pressure at 5.2 bar while for pressure drop for
both condenser and reboiler set at 0 kpa.


12. Nothing to be done at here and continue by clicking the next button.
13


13. At component fraction specs set up all the data. Choose stream.


14. Then set the data for target type for stream.

14


15. Add component methanol.

16. Tick (/) at component fraction-2 and reflux ratio to active.
15


17. Then click start to start the process and wait for the process to converge.



18. Then add valve VLV-100 for the second process for outlet 2.

16


19. Set the delta P at 4.19 bar.


17

20. Add another distillation column. The step is same with distillation column one.


21. Check the duty of the condenser of DC1 to answer question 4.

22. Check the reboiler of DC2.

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23. Check the mole fraction of the bottom product before integrating to answer question no 5.

24. This is the process at distillation 1 and 2 before integrated.
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25. To heat integrated, add the Adjusted equipment to the near TEE-100. Then at the adjusted
variable choose the object=TEE-100, variable=flow rate and variable specifics = flow
ratio 1.


26. At the target variable, set the flow sheet=T-100, object =DC DCT ovhd liquid and
variable=heat flow.
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27. Change the step size to make sure the sign written is ok. For this experiment I use step size is
0.001

28. This is complete process for heat integrated in distillation column.



21

Apparatus and material
1. Distillation column.
2. Valve.
3. Splitter.
4. Methanol.
5. Water

















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Result.

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1. How to reduce pressure in the DC2?
- To reduce pressure in the DC2 we adding valve.
2. What are the calculated reflux ratio of DC1 and DC2?
- The value of reflux ratio of DC1 is 1.26 while for DC2 is 0.834.
3. What is the value of the split ratio of the feed stream for each DC after heat integration?
- The value of the split ratio of the fed stream for each DC after heat integration is
0.4607 for DC1 and 0.593 for DC2.
4. What is the duty of the condenser of DC1 and the reboiler of DC2 before integrating the
heat?
- The duty of the condenser of DC1 is 5.226X10
7
KJ/h while the reboiler of DC2 is
5.552X10
7
KJ/h before integrating.
5. What is the mole fraction of the bottom product in DC2 before and after integrating the
heat?
Before
Bottom Product Methanol Water
Mole Fraction 0.0401 0.9599
After
Mole Fraction 0.0400 0. 9600








24

Discussion.
Based on the objective, we need to simulate the DC with heat integration. The simulation was
done by using HYSYS software. The process is production of methanol is carried out in a
moderate pressure synthesis loop by direct hydrogenation of carbon dioxide, which generates a
liquid product that contains a binary mixture of methanol that is nearly free of water, dehydration
is achieved commonly by distillation. We use heat integration method to reduce the sizable
energy costs.
The components of methanol and water will enter as a feed in material stream. Then, it will enter
the splitter where it will split into 2 streams (out 1 and out 2). The component is equimolar where
0.5 for methanol and water respectively.
The out 1 will enter to distillation column 1 where out 2 will enter to the valve to reduce the
pressure from 5.2bar to 1.01bar. The delta P is 4.19bar. After that, the stream will enter to
distillation column 2. All equipment and data must insert. For reflux ratio of DC1 is 1.26 while
for DC2 is 0.834.
The value of duty of the condenser of DC1 is 5.226X10
7
KJ/h and the reboiler of DC2 is
5.552X10
7
KJ/h before integrating the heat.
To heat integrated method, we should add adjust tool. The adjust tool was used where the
adjustment was done at the splitter until the heat duties of the condenser of DC1 is same or
nearly same with the second reboiler of DC2.
The value of the split ratio of the feed stream for each DC after heat integration is 0.4607 for
out1 while 0.593 for out2. The mole fraction of the bottom product in DC2 before and after
integration is same, 0.04 for methanol and 0.96 for water. That shown, the heat integrated
method will reduce the cost without disturbing the composition of the product at the end of the
process.



25

Conclusion.
I. Heat integrated distillation column has a much higher energy efficiency than either a
normal distillation column
II. Energy discharged from condenser DC 1 is then supplied to the reboiler DC 2
III. the heat integrated method will reduce the cost without disturbing the composition of the
product at the end of the process.
















26

Recommendation.
The problem need to be understand properly before inserting the value and apparatus in
the HYSYS simulation in order to avoid error.
Make sure all the indicator for all stream and apparatus turn to green after inserting the
value, the indicator show all the value commonly need to be add in the information
tables.
Use of SRK fluid package.
Use of SI unit when evaluating the value.

References.
Unit Operation of Chemical Engineering, McGrawhill 7
th
edition, Warren L Mccabe,
Julian C.Smith, Peter Harriot.
Process unit operation, CPE521 lecture notes (semester 3).
http://www.ecn.nl/docs/library/report/2005/rx05157.pdf











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Appendices.

Result before integration.
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Result after integration