Energy efficient control and optimisation techniques for distillation processes

Abstract

Distillation unit is one of the most energy intensive processes and is among the major CO2 emitter in the chemical and petrochemical industries. In the quest to reduce the energy consumption and hence the environmental implications of unutilised energy, there is a strong motivation for energy saving procedures for conventional columns. Several attempts have been made to redesign and heat integrate distillation column with the aim of reducing the energy consumption of the column. Most of these attempts often involve additional capital costs in implementing. Also a number of works on applying the second law of thermodynamics to distillation column are focused on quantifying the efficiency of the column. This research aims at developing techniques of increasing the energy efficiency of the distillation column with the application of second law using the tools of advanced control and optimisation. Rigorous model from the fundamental equations and data driven models using Artificial neural network (ANN) and numerical methods (PLS, PCR, MLR) of a number of distillation columns are developed. The data for the data driven models are generated from HYSYS simulation. This research presents techniques for selecting energy efficient control structure for distillation processes. Relative gain array (RGA) and relative exergy array (REA ) were used in the selection of appropriate distillation control structures. The viability of the selected control scheme in the steady state is further validated by the dynamic simulation in responses to various process disturbances and operating condition changes. The technique is demonstrated on two binary distillation systems. In addition, presented in this thesis is optimisation procedures based on second law analysis aimed at minimising the inefficiencies of the columns without compromising the qualities of the products. ANN and Bootstrap aggregated neural network (BANN) models of exergy efficiency were developed. BANN enhances model prediction accuracy and also provides model prediction confidence bounds. The objective of the optimisation is to maximise the exergy efficiency of the column. To improve the reliability of the optimisation strategy, a modified objective function incorporating model prediction confidence bounds was presented. Multiobjective optimisation was also explored. Product quality constraints introduce a measure of penalization on the optimisation result to give as close as possible to what obtains in reality. The optimisation strategies developed were applied to binary systems, multicomponents system, and crude distillation system. The crude distillation system was fully explored with emphasis on the preflash unit, atmospheric distillation system (ADU) and vacuum distillation system (VDU). This study shows that BANN models result in greater model accuracy and more robust models. The proposed ii techniques also significantly improve the second law efficiency of the system with an additional economic advantage. The method can aid in the operation and design of energy efficient column.