Patent Description:
Distillation accounts for a significant amount of the overall energy usage in many industries, including crude oil refining and petrochemical production. Although over <NUM>,<NUM> distillation columns are used in a broad range of commercial applications, distillation in general is nevertheless characterized as having a low energy efficiency.

Distillation is a separation process that exploits differences (sometimes minor) in component relative volatilities or boiling points. Generally, a high degree of purity of component A (e.g., propane, having three carbon atoms) and component B (e.g., n-butane, having four carbon atoms) can be achieved by distilling an impure mixture of these components. This assumes that the distillation column used provides, in view of the relative volatility difference, a sufficient number of theoretical stages of vapor-liquid equilibrium contacting and that an azeotropic mixture of the components is not formed at a composition below the desired purity.

When separating a mixture of three components A, B, and C (or three fractions that may themselves be mixtures of components) at least two distillation columns are typically used; however, each column is only capable of separating a feed stream into two product streams, namely an overhead product enriched in the lower boiling component(s) and a bottoms product enriched in the higher boiling component(s).

An alternative to the use of two separate distillation columns for separating a mixture into three component streams is a dividing-wall column (DWC). A single DWC can replace the conventional two columns in series designs. Typically, the DWC has a lower energy consumption compared to the conventional two columns in series designs. An exemplary DWC is disclosed in <CIT> or <CIT>.

Despite being presumably effective for their intended purposes, a drawback of some DWC designs is the inability to effectively and efficiently control/split vapor flows across the two sides of the dividing wall. Current solutions to control/split vapor flows include adjusting the position of the dividing wall such that the required vapor flow is achieved on the two sides of the dividing wall by hydraulic pressure drop through the parallel paths on each side of the dividing wall. However, this arrangement poses a limitation, because it does not allow for the vapor flow to be adjusted whenever there is a substantial expected feed composition change or with any process objectives that results in a large, required vapor flow variation on either side of partition/dividing wall. Thus, since the pressure drop on either side of the walled sections is same, there are limitations in the application of DWCs - especially in cases where the flow up through each of the divided sections is must vary.

Therefore, it would be desirable to provide a DWC that does not suffer from these drawbacks and provides a process for separating hydrocarbons in which vapor passed to both sides of the dividing wall may be controlled and varied.

The DWC according to the present invention provides controllable and adjustable vapor flow control on either side of the dividing wall with control valves. This is achieved while retaining a single column configuration by separating the lower and middle portions of the column with a vapor and liquid barrier. With the improved vapor flow control through the dividing wall section, wider application of DWC is believed to be achieved - especially for cases where flow variation on either side of the dividing wall is expected.

The ability to split the total amount of vapors from the bottom section to the two portions of middle section in an adjustable ratio allows the DWC to meet process objectives of separation. This split of vapors is achieved by providing a physical separation of the DWC section with the dividing wall and the lower section using a bottom head between the two sections. This allows the two sections to operate at different pressures.

The benefits of the present invention include the ability to use a DWC even in situations in which there are large feed composition changes or in situations in which the process objectives change, resulting in large, necessary vapor flow variations on either side of partition. Furthermore, installation of the DWC according to the present invention in existing systems where the dividing wall is at a fixed location, provide the ability to control liquid/vapor rates in the two opposing sections of the portion of the DWC with the dividing wall in the desired ratio based on feed quantity/composition.

Therefore, the present invention may be characterized, in at least one aspect, as providing an apparatus for separating a feed composition comprising a plurality of components as defined in the appended claims.

The apparatus includes a first vapor conduit providing vapor flow from the lower section to a first portion of the middle section, and a second vapor conduit providing vapor flow from the lower section to a second portion of the middle section. The apparatus includes a first control valve disposed in the first vapor conduit, and a second control valve disposed in the second vapor conduit. The first and second control valves are configured to be operated independently of each other.

The dividing wall distillation column according to the presently claimed present invention is defined in the appended claims.

The dividing wall column also includes a first vapor conduit providing vapor flow from the third section to a first portion of the second section, and a second vapor conduit providing vapor flow from the third section to a second portion of the second section. The dividing wall column includes a first control valve disposed in the first vapor conduit and a second control valve disposed in the second vapor conduit. The first and second control valves are configured to operate independently of each other. The dividing wall column includes at least one liquid conduit for providing liquid from the second section to the third section.

It is further contemplated that the dividing wall column a first outlet in the first section for a first product stream. It is contemplated, that a first portion of the second section further includes an inlet for a feed composition, and a second portion of the second section further includes a second outlet for a second product stream. The third section may include a third outlet for a third product stream.

In yet another aspect of the present invention, the present invention may be generally characterized as a providing a process for separating a hydrocarbon feed stream as defined in the appended claims.

The hydrocarbon feed stream is passed into one of the two portions of the middle section, and wherein the second product stream is recovered from the other of the two portions of the middle section.

Vapor is passed from the lower section to the middle section with at least two vapor flow conduits. A first vapor flow conduit passes the vapor from the lower section to the first portion of the middle section, and the second vapor flow conduit passes the vapor from the lower section to the second portion of the middle section. A pressure of the first portion may different than a pressure of the second portion.

It is contemplated that process also includes sensing at least one parameter of the process and generating a signal or data from the sensing; generating and transmitting a signal; or generating and transmitting data.

Additional aspects, embodiments, and details of the invention, all of which may be combinable in any manner, are set forth in the following detailed description of the invention.

One or more exemplary embodiments of the present invention will be described below in conjunction with the following drawing figures, in which:.

As mentioned above, the present invention provides a dividing wall column for separating a feed composition comprising a plurality of components by distillation as defined in the appended claims. Generally, the dividing wall column includes three sections, namely, a first or upper section, a second or middle section, and a third or bottom section. The middle section is separated in half, from top to bottom, by a dividing wall. Both portions of the middle section are separated from the lower section by a barrier which precludes vapor and liquid from flowing directly between the two sections. Rather, vapor conduits transfer vapor from the lower section to both portions of the middle section, and liquid conduits transfer liquid form the middle section to the lower section. This configuration allows for the amount of vapor transferred to the two portions of the middle section to be controlled and adjusted to accommodate, for example, changes in feed composition.

With these general principles in mind, one or more embodiments of the present invention will be described with the understanding that the following description is not intended to be limiting.

With reference to both <FIG> and <FIG>, a dividing wall distillation column <NUM> according to a representative embodiment of the invention is shown. The dividing wall distillation column <NUM> may be used in the fractional distillation of a feed comprising a number of different compounds (e.g., hydrocarbon compounds as well as non-hydrocarbon compounds like oxygenates such as alcohols, ketones, and ethers) into an (i) overhead product enriched in one or more low boiling compounds present in the feed, (ii) a bottoms product enriched in one or more high boiling compounds present in the feed, and (iii) a sidecut product enriched in one or more intermediate boiling compounds present in the feed. The term "enriched" in a compound refers to a higher concentration of that compound in the product, relative to the feed. The dividing wall distillation column <NUM> may be employed to perform a wide variety of fractionation operations, particularly in the petroleum and petrochemical industries. These include the separation of hydrocarbons (e.g., having from <NUM> to <NUM> carbon atoms) or other non-hydrocarbon compounds of a feed into fractions having a similar relative volatility or boiling point. Product fractions can include crude oil-derived products of petroleum refining and petrochemical processing, such as naphtha, diesel fuel, kerosene, and liquefied petroleum gas (LPG). In some cases, fractions can be specific compounds, or specific types of compounds, separated from others of the same chemical or functional class, for example alcohols, ethers, alkylaromatics, monomers, solvents, inorganic compounds, etc..

The dividing wall distillation column <NUM> includes three sections, a first or upper section <NUM>, a second or middle section <NUM>, and a third or bottom section <NUM>. For simplicity, conventional vapor-liquid contacting devices such as trays or packing materials are not shown in <FIG> and <FIG>, although these contacting devices are present throughout the three sections <NUM>, <NUM>, <NUM>.

The dividing wall distillation column <NUM> also includes a liquid barrier <NUM> separating the upper section <NUM> and the middle section <NUM>. The liquid barrier <NUM> comprises a first solid tray portion <NUM>, which can include multiple tray sections, for blocking internal, downward liquid flow from the upper section <NUM> to the middle section <NUM> across all or substantially all of the cross section of the dividing wall distillation column <NUM>. At the same time, vapor from the middle section <NUM> may rise and pass through the liquid barrier <NUM> and into the upper section <NUM>.

Accordingly, the liquid barrier <NUM> may include one or more vertically extending, capped upper vapor risers <NUM>. As shown in <FIG> and <FIG>, the liquid barrier <NUM> is not necessarily coplanar, but may include features such as upper vapor risers <NUM> and/or collection well <NUM>, extending above and/or below the plane of the solid tray portion <NUM>. According to a particular embodiment, the liquid barrier <NUM> comprises a solid tray, such as a chimney tray, extending over a circular cross section of the column and further comprises a plurality of vapor risers.

The dividing wall distillation column <NUM> also includes a solid vapor and liquid barrier <NUM> separating the middle section <NUM> from the lower section <NUM>. The solid vapor and liquid barrier <NUM> blocks substantially all of both the internal, upward flow of vapor from the lower section <NUM> to the middle section <NUM> and the internal, downward flow of liquid from the middle section <NUM> to the lower section <NUM>. The solid vapor and liquid barrier <NUM> comprises a solid wall, or bulkhead, that may be curved, as depicted. Other configurations are contemplated. Additionally, the solid vapor and liquid barrier <NUM> preferably has sufficient structural integrity to allow for a pressure differential to exist between the middle section <NUM> and the lower section <NUM>.

In the dividing wall distillation column <NUM>, the middle section <NUM> is divided into two portions 28a, 28b by a dividing wall <NUM> extending along a longitudinal axis of the dividing wall distillation column <NUM>. The two portions 28a, 28b preferably extend parallel to each other and the longitudinal axis of the dividing wall distillation column <NUM>. The dividing wall <NUM> extends from the liquid barrier <NUM> to the vapor and liquid barrier <NUM> to provide the two portions 28a, 28b.

Additionally, as shown in the depicted embodiment the dividing wall distillation gf column <NUM>, includes upper liquid conduits 32a, 32b which are used to provide liquid flow from above upper section <NUM>, around the liquid barrier <NUM>, to the portions 28a, 28b of the middle section <NUM>. The upper liquid conduits 32a, 32b are preferably external to the dividing wall distillation column <NUM> and thereby readily controlled using control valves and flow measurement systems (not shown). The material in liquid conduits 32a, 32b may be conveyed to the portions 28a, 28b of the middle section <NUM> using pumps (not shown) or otherwise via gravity in the case of a free draining system. Conduits 32a, 32b normally terminate at liquid flow distributors (not shown) within the dividing wall distillation column <NUM>.

Similarly, as shown in <FIG>, the dividing wall distillation column <NUM> also includes lower liquid conduits 34a, 34b which may be used to provide liquid flow from the middle section <NUM>, around the solid vapor and liquid barrier <NUM>, to the lower section <NUM>. The lower liquid conduits 34a, 34b are preferably external to the dividing wall distillation column <NUM> and thereby readily controlled using control valves 36a, 36b and level indicators 38a, 38b. The material in liquid conduits 32a, 32b may be conveyed to the lower section <NUM> using pumps (not shown) or otherwise via gravity in the case of a free draining system. Lower liquid conduits 34a, 34b normally terminate at liquid flow distributors (not shown) within the dividing wall distillation column <NUM>. The control valves 36a, 36b help to maintain a pressure seal between the middle section <NUM> and the lower section <NUM>.

Returning to <FIG>, in order to bypass the solid vapor and liquid barrier <NUM> and provide for vapor flow between the portions 28a, 28b of the middle section <NUM> and the lower section <NUM> of the dividing wall distillation column <NUM>, the dividing wall distillation column <NUM> includes vapor conduits 40a, 40b or lines for vapor streams. The vapor conduits 40a, 40b are preferably external to the dividing wall distillation column <NUM>. Each vapor conduit 40a, 40b includes a control valve 42a, 42b allowing the flow of vapor to be regulated. The control valves 42a, 42b are configured to be operated independently of each other allowing different amounts of vapor to be passed from the lower section <NUM> to the portions 28a, 28b of the middle section <NUM>. The vapor flow rates through each of the control valves 42a, 42b may be monitored by instrumentation, such as with flow indicators 44a, 44b, for example which measures a pressure drop across each of the control valves 42a, 42b. The control valves control valve 42a, 42b are configured to be operated independently of each other allowing different amounts of vapor to be passed from the lower section <NUM> to the portions 28a, 28b of the middle section <NUM>. Vapor conduits 40a, 40b normally terminate at vapor flow distributors (not shown) within the dividing wall distillation column <NUM>.

The dividing wall distillation column <NUM> also comprises an inlet <NUM> for a feed stream <NUM>, a first outlet <NUM> for an overhead stream <NUM>, a second outlet <NUM> for a sidecut stream <NUM>, and a third outlet <NUM> for a bottoms stream <NUM>. This is merely exemplary and other configurations may be used for the dividing wall distillation column <NUM>. For example, the dividing wall distillation column <NUM> may include multiple inlets for the feed stream <NUM>. Similarly, the dividing wall distillation column <NUM> may include additional outlets for additional product streams, for example, a second outlet in the middle section <NUM> for a second sidecut stream.

As depicted in <FIG> and <FIG>, the first outlet <NUM> is associated with the upper section <NUM> of the dividing wall distillation column <NUM>. As is known, the overhead stream <NUM> may be passed through a condenser <NUM> to provide a liquid stream <NUM>, a portion 62a of which passed back to the upper section <NUM> of the dividing wall distillation column <NUM> as a reflux, while a second portion 62b is recovered as a first product stream. The condenser <NUM> may be an external condenser (as shown) or the condenser <NUM> may be an internal condenser. Additionally, multiple condensers <NUM> may be used, as well as the same or different types of condensers <NUM> (e.g., air and water cooled condensers) to control, in conjunction with an overhead receiver or reflux drum (not shown) and an overhead reflux pump, flow device, and control valve (not shown) (i) the extent of condensation of vapor removed from the upper section <NUM>, (ii) the extent of condensed liquid returned to the dividing wall distillation column <NUM>, and the first product stream withdrawn from, the upper section <NUM>, and (iii) the dividing wall distillation column <NUM> temperature in the upper section <NUM>.

In the exemplary dividing wall distillation column <NUM> of the present invention, the inlet <NUM> and the second outlet <NUM> are associated with the middle section <NUM> of the dividing wall distillation column <NUM>. Preferably, the inlet <NUM> is associated with the first portion 28a of the middle section <NUM>, while the second outlet <NUM> is associated with the second portion 28b of the middle section <NUM>. The second portion 28b may include a tray <NUM> for collecting liquid, such as chimney tray with system vapor risers <NUM> and a sidecut collection well <NUM>. The sidecut stream <NUM> may also be passed, as is known, through a condenser (not shown) to provide a condensed sidecut stream. A portion 70a of the condensed sidecut stream <NUM> may be passed back to the column as a reflux stream. A second portion 70b of the condensed sidecut stream is recovered as a second product stream.

Finally, as shown in the depicted dividing wall distillation column <NUM> of <FIG> and <FIG>, the third outlet <NUM> is associated with the lower section <NUM> of the column <NUM>. As is known, first portion 80a of the bottoms stream <NUM> is returned to the dividing wall distillation column <NUM>, while a second portion 80b is recovered as a third product stream. The first portion 80a of the bottoms stream <NUM> may be passed to through a bottoms liquid reboiling system that includes bottoms reboiler <NUM>, which may be an external reboiler or an internal reboiler. One or multiple reboilers <NUM> may be used, as well as the same or different types of reboilers <NUM> to control, in conjunction with a bottoms circulation control valve (not shown) (i) the extent of vaporization of liquid removed from lower section <NUM>, (ii) the extent of vaporized liquid returned to, and bottoms product withdrawn from, lower section <NUM>, and (iii) the dividing wall distillation column <NUM> temperature in this section. Other measurement systems (e.g., for temperature measurement) may be used in the overhead liquid condensation and reflux system and/or the bottoms liquid reboiling system, often as part of a control loop.

Embodiments of the invention are therefore directed to fractionation methods comprising passing the feed stream <NUM> comprising, for example, hydrocarbons or other compounds as described above into the dividing wall distillation column <NUM> depicted in <FIG> and <FIG> and described above. Representative methods further comprise blocking all or substantially all of a downward liquid flow from the upper section <NUM> of the dividing wall distillation column <NUM> to the middle section <NUM> of the dividing wall distillation column <NUM> with a liquid barrier <NUM>. The methods also comprise blocking all or substantially all of upward vapor flow from the lower section <NUM> the dividing wall distillation column <NUM> to the middle section <NUM> and also blocking all or substantially all of downward liquid flow from the middle section <NUM> to the lower section <NUM> with the solid vapor and liquid barrier <NUM>. The methods include passing a first vapor stream 40a from the bottoms section <NUM> to the first portion 28a of the middle section <NUM> and a passing a second vapor stream 40b from the bottom section <NUM> to the second portion 28b of the middle section <NUM>. The amounts of the vapor in the first and second vapor stream 40a, 40b may be adjusted based on changes in feed stream <NUM> composition which require flow variation between the two portions 28a, 28b of the middle section <NUM> for effective and efficient separation into the product streams 62b, 70b, 80b. The methods include adjusting the flow of the vapor streams 40a, 40b independently from each other. The methods may further comprise withdrawing (i) a first or overhead stream <NUM>, enriched in low boiling hydrocarbons, from the column <NUM> above the liquid barrier <NUM>, (ii) withdrawing a second or sidecut stream <NUM>, enriched in intermediate boiling hydrocarbons, from the middle section <NUM> of the dividing wall distillation column <NUM>, and (iii) withdrawing a third or bottoms stream <NUM>, enriched in high boiling hydrocarbons, from the column <NUM> below the solid vapor and liquid barrier <NUM> of the dividing wall distillation column <NUM>.

Any of the above lines, conduits, units, devices, vessels, surrounding environments, zones or similar may be equipped with one or more monitoring components including sensors, measurement devices, data capture devices or data transmission devices. Signals, process or status measurements, and data from monitoring components may be used to monitor conditions in, around, and on process equipment. Signals, measurements, and/or data generated or recorded by monitoring components may be collected, processed, and/or transmitted through one or more networks or connections that may be private or public, general or specific, direct or indirect, wired or wireless, encrypted or not encrypted, and/or combination(s) thereof; the specification is not intended to be limiting in this respect.

Signals, measurements, and/or data generated or recorded by monitoring components may be transmitted to one or more computing devices or systems. Computing devices or systems may include at least one processor and memory storing computer-readable instructions that, when executed by the at least one processor, cause the one or more computing devices to perform a process that may include one or more steps. For example, the one or more computing devices may be configured to receive, from one or more monitoring component, data related to at least one piece of equipment associated with the process. The one or more computing devices or systems may be configured to analyze the data. Based on analyzing the data, the one or more computing devices or systems may be configured to determine one or more recommended adjustments to one or more parameters of one or more processes described herein. The one or more computing devices or systems may be configured to transmit encrypted or unencrypted data that includes the one or more recommended adjustments to the one or more parameters of the one or more processes described herein.

For example, upon receiving a signal or data relating to the composition of the feed stream <NUM>, or a level in one of the portions 28a, 28b of the middle section <NUM>, a computing device or system may be configured to send a signal to the control valves 42a, 42b in the vapor conduits 40a, 40b to adjust the amount of vapor flowing into one or both of the portions 28a, 28b of the middle section <NUM>. The control valves 42a, 42b in the vapor conduits 40a, 40b may be in communication with a computing device (not shown), with for example radio transmitters and receivers. The computer device may be configured to send signals to the control valves 42a, 42b to adjust the ratio of vapor flowing into the two portions 28a, 28b of the middle section <NUM>. The adjustment of the control valves 42a, 42b may be to achieve a desired ratio or it can be a responsive adjustment not based on achieving a desired ratio, but based on one or more processing conditions that are detected or determined to be present, such as a feed composition, a product composition, a temperature, a pressure, a level, or the like.

It should be appreciated and understood by those of ordinary skill in the art that various other components such as valves, pumps, filters, coolers, etc. were not shown in the drawings as it is believed that the specifics of same are well within the knowledge of those of ordinary skill in the art and a description of same is not necessary for practicing or understanding the embodiments of the present invention.

Without further elaboration, it is believed that using the preceding description that one skilled in the art can utilize the present invention to its fullest extent and easily ascertain the essential characteristics of this invention, without departing from the scope thereof, to make various changes and modifications of the invention and to adapt it to various usages and conditions. The preceding preferred specific embodiments are, therefore, to be construed as merely illustrative, and not limiting the remainder of the disclosure in any way whatsoever. The scope is defined by the appended claims.

In the foregoing, all temperatures are set forth in degrees Celsius and, all parts and percentages are by weight, unless otherwise indicated.

Claim 1:
A dividing wall distillation column (<NUM>) comprising:
a first section (<NUM>) having a tray (<NUM>) that is a liquid barrier (<NUM>) for collecting a first liquid;
a second section (<NUM>) disposed below the first section (<NUM>), the second section (<NUM>) comprising two portions (28a, 28b) separated from each other by a dividing wall (<NUM>), wherein the liquid barrier (<NUM>) of the first section (<NUM>) is configured to block the first liquid from flowing from the first section (<NUM>) into either of the two portions (28a, 28b) of the second section (<NUM>); and,
a third section (<NUM>) separated from the second section (<NUM>) by a solid vapor and liquid barrier (<NUM>) configured to block a flow of vapor from the third section (<NUM>) to the second section (<NUM>) and block a flow of liquid from the second section (<NUM>) to the third section (<NUM>);
a first vapor conduit (40a) providing vapor flow from the third section (<NUM>) to a first portion (28a) of the second section (<NUM>);
a second vapor conduit (40b) providing vapor flow from the third section (<NUM>) to a second portion (28b) of the second section (<NUM>); and
at least one liquid conduit (34a, 34b) for providing liquid from the second section (<NUM>) to the third section (<NUM>);
a first control valve (42a) disposed in the first vapor conduit (40a); and,
a second control valve (42b) disposed in the second vapor conduit (42b);
wherein the wall (<NUM>) extends from the liquid barrier (<NUM>) to the vapor and liquid barrier (<NUM>) to provide the two portions (28a, 28b);
wherein the first and second control valves (42a, 42b) are configured to operate independently of each other.