Energy, exergy, and economic analyses and optimization of a deethanizer tower of a petrochemical plant

Abstract

Abstract The distillation tower’s reboiler is one of the largest energy consumers in petrochemical facilities, and reducing its energy consumption is a crucial issue. This study proposes two optimal methods, namely Direct Vapor Recompression (DVR) and External Vapor Recompression (EVR), to reduce the consumption of cold and hot utilities in a petrochemical deethanizer tower. The Pars petrochemical in Iran is taken as a case study, and the proposed methods are compared with the base case using energy, exergy, and economic approaches, simulated through Aspen HYSYS software in the steady-state design conditions. Exergy analysis reveals that the EVR and DVR methods reduce the exergy destruction of the deethanizer tower by about 70.06 % and 67.29 %, respectively, compared to the base case. Moreover, the EVR method allows for complete recycling of low-pressure vapor, reducing the total exergy destruction rate from 0.871 to 0.261 GJ/tethane. The feed separation cost for the base case, DVR, and EVR are estimated to be around 28 $/kgfeed, 21.57 $/kgfeed, and 21.14 $/kgfeed, respectively. The EVR method results in reduced utility and ethane separation cost rates from 5.153 to 3.274 $/tethane and 17.64 to 15.78 $/year. Overall, the findings suggest that both DVR and EVR methods are effective in reducing the energy consumption and costs associated with deethanizer tower operations. Moreover, real-time optimization techniques can be developed to monitor and adjust the deethanizer tower’s operating parameters, such as feed flow rate, reboiler duty, and reflux ratio.