Process Dynamic and Control For Nonconventional Co

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IOP Conference Series: Materials Science and Engineering

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Process Dynamic and Control for Nonconventional Column/Rectifier


Configuration with Aspen Hysys v10.0
To cite this article: R A Hikmadiyar et al 2019 IOP Conf. Ser.: Mater. Sci. Eng. 543 012049

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1st International Symposium of Indonesian Chemical Engineering (ISIChem) 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 543 (2019) 012049 doi:10.1088/1757-899X/543/1/012049

Process Dynamic and Control for Nonconventional


Column/Rectifier Configuration with Aspen Hysys v10.0

R A Hikmadiyar1, J P Sutikno1, R Handogo1, Z Azizah1, A Hisyam2


1
Department of Chemical Engineering, Institut Teknologi Sepuluh Nopember,
Surabaya 60111, Indonesia
2
Faculty of Chemical and Natural Resources, University Malaysia Pahang, Malaysia

E-mail: [email protected]

Abstract. Nonconventional column/rectifier configuration is the new alternate design for the
sequence multicomponent separation of three or more products. It can accomplish an efficient
energy. There are two columns, the first is the rectifier and the second is the main, the vapor
sidestream is taken out from the location under the feed tray of the main column then fed to the
rectifier column and the liquid that from the bottom of the rectifier column is turned back to the
main column. In order to completely understand the dynamic behavior of complex process of
this configuration, process dynamic and control of it has to be studied intensively. The
implementation of it is demethanizer and deethanizer column. The configuration has been
simulated for dynamic by using Aspen Hysys v10.0. The results show that the graph of rejecting
disturbance from all controllers of the main column need more attention especially for inventory
control i.e. level controller for reflux drum, sump level reboiler and pressure controller for
condenser. The overshoot for level controller of reflux drum of main column is 10% from set
points. The better algorithm of tuning is required. The results of this studied could provide
guidance for composition controller of this configuration.

1. Introduction
The sequence multicomponent separation of three or more products is usually performed in distillation
column with conventional configuration [1]. Many research have studied for conventional configuration
in distillation column, and the results showed that it has consumed excessive energy [2]. Increasing the
need for an efficient energy, the alternate design for distillation column is required. Nonconventional
column/rectifier configuration is one the alternate design for nonconventional column configuration in
distillation process [3]. Thermally coupled distillation sequence was used for the basic concept for
nonconventional column/rectifier configuration system. Several studies have reported it [4][5][6][7][8].
It does not use reboiler but still uses condenser. There are two columns, the first is the rectifier column
and the second is the main column, the vapor sidestream is taken out from the location under the feed
tray of the main column then fed to the rectifier column and the liquid that from the bottom of the main
column is turned back to the main column [3]. Energy and cost saving can be accomplished by it [6].
The significant problem of nonconventional column/rectifier configuration is the recycle stream in
requirement for the dynamic and control [5]. It has been proof that plant uses the recycle system is more
profit in steady state condition, because it can minimize the operation cost [9]. When in dynamic system

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Published under licence by IOP Publishing Ltd 1
1st International Symposium of Indonesian Chemical Engineering (ISIChem) 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 543 (2019) 012049 doi:10.1088/1757-899X/543/1/012049

it need more caution [5]. Process simulator such as Aspen Hysys gives good enviroments for dynamic
simulation of distillation column in addition to PID controller [10]. In order to completely understand
the dynamic behavior of complex process of nonconventional column/rectifier configuration, so the
study about process dynamic and control of nonconventional colom/rectifier using process simulator i.e.
Aspen Hysys is being important.

2. General study

2.1. Process description


The process chosen for this study is a modified demethanizer and deethanizer column [3]. Methane is
mostly involved in Natural Gas coming from wells. The other important component is ethane, propane,
and heavier hydrocarbons. Demethanizer and deethanizer column separate methane, ethane and propane
with the heavier hydrocarbons. The top products of demethanizer are methane and small amount of
ethane, the top and bottom products of deethanizer are ethane and propane with the heavier hydrocarbons
[11]. There are many reasons why methane, ethane, propane and heavier hydrocarbons are separated
from natural gas wells. The reasons depend greatly on the commercial products requirement. For
Liquefied Natural Gas (LNG) requirement, ethane and propane with the heavier hydrocarbons have to
be removed to avoid the solid formations at low temperature [3].

2.2. Process simulation


Demethanizer and deethanizer column used nonconventional column/rectifier configuration.
Demethanizer was the rectifier column and deethanizer was the main column. Demethanizer had 8
stages and 31 stages for deethanizer. Feed entered the second stage of demethanizer column. The vapor
sidestream was retreated from the seventh stage of deethanizer column then settled to the base stage of
demethanize column and the liquid from the base of demethanizer column was fed back to seventh stage
of deethanizer column [3].
Process Flow Diagram (PFD) from demethanizer and deethanizer column was simulated by Aspen
Hysys v10.0. In flowsheet of Aspen Hysys, Demethanizer column used Refluxed Absorber Column
model. It had a tower and condenser but no reboiler. For steady state, demethanizer column was
specified 1479 kmol/hr for the distillate rate and 2950 kmol/hr for vapor sidestream rate. Deethanizer
column used Distillation model. Distillation model has tower with both a condenser and reboiler. To
achieve convergence simulation, deethanizer column has three specifications i.e. 507.2 kmol/hr for the
distillate rate, 0.784 for reflux ratio, and 2950 kmol/hr for vapor sidestream rate. For dynamic
requirement, demethanizer column needed vessel for liquid level control in the bottom of column.
Pressure changers like valve, pump and compressor were added. Pump was added to transfer liquid from
the base of the demethanizer column to seventh stage to deethanizer column. Compressor was given to
transfer vapor from the deethanizer to demethanizer column. Valves were added in streams that will be
the manipulated variables.

2.3. Control strategy


The purpose of control system was to keep the purity of methane, ethane, and propane. Nonconventional
column/rectifier configurations had ten degree of freedoms i.e. Feed rate (“F”) two distillates rate (“D”),
one bottom product rate(“B”), Vapor sidestream (“Vss”), reflux rate (“R”) one reboiler duty (“Qr”), and
two condensor duty (“Qc”). The stability of column was made by keeping levels in reflux drum, column
bottom of the main column and top pressure of column.
This study focusses on the control configuration that will influence the dynamic behavior of
nonconventional column/rectifier configuration. The control configuration for demethanizer and
deethanizer column is designed with the inventory control. It will keep the production rate and mass
balance [7]. Vapor sidestream flowrate is controlled. Because vapor sidestream is the recycle stream so
it has to be controlled [12]. When this configuration in dynamic mode, the recycle stream that from
vapor sidestream makes trouble for level controller. The recycle stream is free flow when it is not

2
1st International Symposium of Indonesian Chemical Engineering (ISIChem) 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 543 (2019) 012049 doi:10.1088/1757-899X/543/1/012049

controlled. It becomes a disturbance for level controller especially for level controller system in the main
column. The dynamic model uses pressure changer i.e. Compressor and pump. They need attention
when temperature on the reboiler suddenly increases or decreases. When it suddenly increase, it causes
the entry of vapor in pump. On the contrary if it suddenly decreases, it generates the entry of liquid in
compressor. As a result the temperature controller is required. Figure 1 below shows the proposed
control configuration.
All controllers that used in nonconventional column rectifier/configuration was PID controller. Flow
controller was put on feed. Levels in reflux drum were made by choosing distillate rate as manipupated
variables. Flow controller was put on Vapor sidesstream to control the vapor rate rate from the main
column that was treated to rectifier column. Pressures in top column were controlled by making
condensor duty as manipulated variables and levels in the bottom of columns were controlled by chosing
bottom product rate as manipulated variables. Because the main column had reboiler so temperature
controller was added to keep purity the bottom product of the main column.
PC1 PC2

LC1 LC2

FC1

C1 C2

Feed
TC

FC Vapor

LC Sump 1

LC Sump 2
C3+

De Methanizer De Ethanizer
(Rectifier Column) (Main Column)

Figure 1. The proposed control configuration.

3. Results and discussion


Demethanizer and deethanizer with nonconventional column/rectifier configuration is simulated for
dynamic by using Aspen Hysys v10.0. The proposed control configuration in Figure 1 is implemented
in flowsheet of Aspen Hysys. All Controllers uses Proportional Integral Derivative (PID) controller.
Tuning parameter for PID controller is got by Autotuner in Aspen Hysys v10.0. It uses the oscillations
that will be got Ku or the ultimate gain and Pu or the ultimate periode [13]. The ultimate gain is
formulated as Eq(1) below:
4h
Ku  (1)
a
After getting the ultimate value, the PID tuning parameters are computed by the rule of Tyréus-Luyben
as Equations (2) – (4) below:
Ku
Kc  (2)
2.2
 I  2.2Pu (3)

3
1st International Symposium of Indonesian Chemical Engineering (ISIChem) 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 543 (2019) 012049 doi:10.1088/1757-899X/543/1/012049

Pu
D  (4)
6.3

For tracking set points and rejecting disturbances, Plant in Aspen Hysys v10.0 is given new set points.
Disturbances is given by changing the flowrate of feed with adding +10% and-10%. Figure 2a until
Figure 2h below show the results of set points and rejecting disturbances for each controller.

"a" "b"
2965 FIC Vapor 60 LIC 1
Flowrate (kgmole/h)

FIC-Vapor - SP [kgmole/h] LIC-1-SP [%]

Level Percent (%)


2960 FIC-Vapor - D+10% LIC-1 -D+10% [%]
[kgmole/h] LIC-1 - D-10% [%]
2955 FIC-Vapor - D-10% 50
[kgmole/h]

2950

2945 40
0 5000 10000 15000 20000 25000 0 10000 20000 30000 40000
Time (seconds) Time (seconds)
"c" "d"
LIC 2 LIC Sump 1
60 LIC-2 - SP [%] 60 LIC-Sump1 - SP [%]
LIC-2 - D+10% [%]
Level Percent (%)

Level Percent (%)

LIC-2 - D-10% [%] LIC-Sump1 - D+10% [%]

LIC-Sump1 - D-10% [%]


50 50

40 40
0 10000 20000 30000 40000 0 10000 20000
Time (seconds) Time (seconds)

"e" "f"
60 LIC Sump 2 3120 PIC Cond 1

LIC-Sump2 - SP [%]
Level Percent (%)

Pressure (kPa)

55 LIC-Sump2 - D+10% [%] 3110 PIC-cond1 - SP [kPa]


LIC-Sump2 - D-10% [%] PIC-cond1 - D+10% [kPa]
PIC-cond1 - D-10% [kPa]

50 3100

45 3090
0 10000 20000 30000 40000 50000 0 5000 10000 15000 20000
Time (seconds) Time (seconds)

"g"
69 TIC 3120
"h"
PIC Cond 2
TIC- SP [C] 3115
Temperature (C)

Pressure (kPa)

PIC-cond2 - SP [kPa]
68 TIC- D+10% [C]
3110 PIC-cond2 - D+10% [kPa]
TIC-D-10% [C]
3105 PIC-cond2 - D-10% [kPa]
67
3100

3095
66
0 5000 10000 15000
0 5000 10000 15000 20000 25000 30000
Time (seconds)
Time (seconds)

Figure 2a: Response of Flow controller for vapor sidestream. 2b: Response of Level controller for
reflux drum in the rectifier column. 2c: Response of Level controller for reflux drum in the main

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1st International Symposium of Indonesian Chemical Engineering (ISIChem) 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 543 (2019) 012049 doi:10.1088/1757-899X/543/1/012049

column. 2d: Response of Level controller for sump level reboiler in the rectifier column. 2e: Response
of Level controller for sump level reboiler in the main column. 2f: Response of Pressure controller for
condenser in the rectifier column. 2g: Response of Temperature controller in the main column. 2h:
Response of Pressure controller for condenser in the main column.

4. Conclusion
Demethanizer and deethanizer with nonconventional column/rectifier configuration has been simulated
for dynamic by using Aspen Hysys v10.0. The proposed control configuration has been implemented in
flowsheet Aspen Hysys v10.0. The results show that the level controller of reflux drum in the main
column is most in need of attention for this proposed control configuration of Demethanizer and
Deethanizer with nonconventional column/rectifier configuration. The implementation for other better
tuning is required for it. The proposed control configuration can be used for composition control by
creating methane from the top product of the rectifier column and ethane from the top product of the
main column as process variables, and making reflux rate of the rectifier column and reflux rate of the
main column as manipulated variables.

Acknowledgments
Thanks to Institut Teknologi Sepuluh Nopember (ITS) through LPPM ITS, Chemical Engineering
Department FTI-ITS, and Process Design and Control Laboratory Chemical Engineering ITS.

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1st International Symposium of Indonesian Chemical Engineering (ISIChem) 2018 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 543 (2019) 012049 doi:10.1088/1757-899X/543/1/012049

[13] Åström K J and Hägglund T 1984 Automatic Tuning of Simple Regulators IFAC Proc. 17 1867–
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