Iranian Journal of Oil and Gas Science and Technology
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Enhancing Energy Efficiency in Ideal Binary Distillation through Dynamic Process Intensification

Document Type : Research Paper

Authors

Ali Hosseinpour 1
Reza Mosayebi behbahani 2

1 1 MS, Department of Chemical and Petroleum Engineering, Sharif University of Technology, Tehran, Iran

2 2 PhD, Gas Engineering Department, Ahvaz Faculty of Petroleum Engineering, Petroleum University of Technology (PUT), Ahvaz, Iran

10.22050/ijogst.2025.469181.1713
Abstract
This study examines and optimizes operational strategies in distillation units. Given rising energy costs, limited energy resources, and increasing environmental constraints, improving the energy efficiency of process industries has become critically important. This research aims to enhance the performance of distillation units by implementing dynamic process intensification, which involves alternating between two operational points with different concentrations. The study evaluates the use of Proportional-Integral-Derivative (PID) controllers and Model Predictive Control (MPC) to improve the efficiency of distillation columns. The results show that MPC controllers markedly enhance distillation performance compared to PID controllers. The findings further indicate that optimal periodic operation between the two operational points requires identifying the specific points and the time intervals during which the system should operate in each mode. This research demonstrates that using PID and MPC controllers to manage concentration transitions between operational points can dynamically improve the distillation of methanol and 1-propanol mixtures. As a result, energy savings of approximately 1.5% and 4.5% in the reboiler duty of the distillation column can be achieved without compromising product quality or throughput. Simulations performed in Aspen software validate these outcomes and underscore the positive effects of dynamic process intensification on distillation performance (Kister et al., 1992; Smith 2005).

Highlights

·       Dynamic process intensification is implemented in an ideal binary distillation column.

·       Periodic operation between auxiliary operating points leads to a reduction in reboiler energy consumption.

·       Nonlinear steady-state behavior enables energy savings without compromising product quality.

·       Model predictive control (MPC) outperforms conventional PID control in managing dynamic transitions.

·       A reduction of up to 4.5% in reboiler duty is achieved through the application of MPC.

Keywords

Binary Distillation, Dynamic process intensification, Energy efficiency
PID control
Model predictive control
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  • Receive Date 22 July 2024
  • Revise Date 10 October 2024
  • Accept Date 19 January 2025

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