REPORT ON

SIM-A-THON

SIM-A-THON'17: A Simulation Hack was organised by AIChE VIT at VIT

University, Vellore on 24th-25th March'17 and students of chemical
engineering department actively participated in the event.
The primary objective of SIM-A-THON was to teach students the operating
fundamentals of a distillation system using dynamic simulation.
Pro Simulator software was used for Distillation column program
operation. Pro Simulator provides opportunities to identify the main
equipments associated with distillation systems, to describe the operation of
Depropanizer column, how to start up and shutdown the process using
documented procedures, how to respond safely and efficiently to disturbances
and malfunctions in the process, understand how temperature and pressure
affect the operation of a distillation tower.

GUIDELINES
l. SlM-A-THON was a team participation event every team can had a
maximum of six
members.
2.The event started on 24-Mar-2017 at 7:00 PM and ended on 25-Mar-2017 at
01:00 PM
3. Every team was allotted with a designated system for the simulation event
and
they were not allowed to turn off the systems in between the event.

4. Regular checkpoints were carried out as per the timings given below to
provide
quick guidance as well as interim assessment towards the solution approach

Checkpoint I- 11.00 PM on 24-Mar-20 l 7

Checkpoint II - 02:00 AM on 25-Mar-2017
Checkpoint llI - 09:00 AM on 25-Mar-20l7

5. Periodic save of the simulation work was mandatory, every once in an hour
6. The disturbances and failures to the distillation column as explained ln the
problem statement were manually introduced into the column. Teams were
advised to avail outcome within the designated hours
7.The final solution of the complete problem was meant to be shown on last
checkpoint to the officials and the team having highest order of steady state
and minimum deviation from the design value conditions clearly wins the
event.

PROBLEM STATEMENT
Separation is one of the main chemical engineering operation/process practiced in
industry throughout the world to get high purity products Distillation is one of the
most important separation operations. In general, the purity of the product streams
of a distillation column is controlled by "Distributed Control System (DCS)
For the given problem context, a mixture containing propane and butane is to be
separated into two streams - one enriched in propane (>97 mol% pure) and the other
enriched in butane (>99 mol% pure). in a depropanizer column. Depropanizer
distillation column receives hydrocarbon feed and separates it into propane and
butane from the heavier natural gasoline components. To train the students for the
industry requirement. the prosimulator software package is provided with different
industrial system, including depropanizer distillation column, with DCS. Students
were advised to imagine themselves as process simulation engineer so, they become
responsible for production and control of depropanizer column. As an engineer
working in shifts with other fellow team members to perform simulation to solve the
problem statement and bringing the system to a steady state by handling given
failures and disturbances in an efficient and effective manner.
The following activities were carried out while working on the problem statement
l) Time: 07:00 PM of Day (0 hours from the start)
The distillation column initially was in shutdown condition and the objective was to
start up the column and reach the design condition with a propane stream purity of
97.2%. i.e. From the cold start" of the depropanizer column to the steady stale, to
achieve propane stream with n purity of 97.2% (design value)
2). Time: 11:00 PM of Day l (4 hours from the start)
Main feed pump fails with irrecoverable working conditions. Troubleshoot the
process to retrieve the steady state condition again

3) Time: 09:00 AM of Day 2 (14 hours from the start)

To fulfil market requirements propane was to be produced with 97.5% purity
may. Simulate the process to adjust this disturbance and reach back the new steady
state accommodating point 2.

The design values of depropanizer column are mentioned below. Participants were
working on the simulator to achieve these design values with minimum amount of
deviations.

PROCESS DESCRIPTION
The distillation plant receives hydrocarbon feed and separates into two fractions:
propane, and butane, from the heavier natural gasoline components by the process
of distillation.
The following paragraphs describe the process flow through the simulated plant.
Depropanizer Column

The raw feed is transferred by pump to the inlet of the Depropanizer column, at
tray 18.

The feed enters the column through a control valve, FIC001 and is distributed via a
staggered lateral inlet.

Saturated steam circulation supplies heat for the distillation process by circulation
through the tube side of the kettle type bottoms reboiler, E-001.

The liquid inlet to the reboiler is taken from tray 1 of the column, a total draw-off
tray with two nozzles.

The hot vapor from the reboiler returns to the column below tray 1, while the
reboiled liquid flows by gravity directly to the base of the column.

The column temperature at tray 5 determines the reboiler heat input.

The temperature controller, TIC001, at tray 5 acts on cascade flow control, FIC002,
to regulate the supply of saturated steam to the reboiler.

The tray 5 temperature therefore, controls the column bottoms product

composition.

The bottoms column liquid is transferred without a pump, on level control,

LIC001, to the inlet of debutanizer column.

The pressure differential existing between the two columns is the driving force
for the flow.

The overhead vapor product of the depropanizer is cooled and partially

condensed by passing the entire vapor through an air fan condenser ,E-002, which
consists of four fin-fans.
The degree of condensation is a function of the column pressure, which is
controlled by a split-range pressure controller, PIC001.

This pressure is controlled at the tower top by adjusting the variable pitch of the
cooler fans.

If the air fans cannot provide sufficient cooling, the pressure controller acts on
split-range control on a vent valve to the flare system.

The condensed overhead product then enters the reflux drum, where
vapor/liquid gravity separation occurs

The liquid phase from the reflux drum is returned to the column as reflux. The
reflux is pumped back to the column by reflux pump above the top tray, tray 40,
through a spray pipe distributor.

The reflux return to the column is controlled by FIC003, which allows the reflux
ratio to be altered to maintain the top product purity.

Level control, LIC002, of the reflux drum is achieved by cascade control of the
top product flow, FIC004. The vapor phase of the drum is the overhead product of
the Depropanizer column.

Care should be taken between each flow adjustment to allow ample time for the
columns to adjust to the new flow rates.

It is important to maintain the proper product purities always.

CONCLUSION

The 24 hours session on Pro-Simulator was very beneficial for the students as they
came across the real life Industrial Design Problem. Problem Statement was
strenuous but students deciphered it very well and the final results were great.
Results reflected minimum deviations from the design value conditions and error
percentage diminished.

They could maintain the temperature, pressure and other parameters accurately to
obtain highest level of purity and less emission of exhaust gases as per the
environmental conditions.

This innovative and efficient training session conducted by AIChE enabled them to
avail the knowledge of basics of a process control engineer and the working of
Distillation column program operation effectively.