TROUBLESHOOTING OF DISTILLATION

COLUMNS USING ASPEN PLUS

Presented By:
ARITRA CHAKRABARTY SENGUPTA
Simulation and Modelling Group, RTG, RIL

DISCLAIMER
Any statement, opinion, prediction, comment, or observation made in this
presentation/publication are those of the presenter/author only and in no condition
should be construed necessarily representing the policy and intent of Reliance
Industries Ltd. (RIL).
The information presented herein are of the presenter/authors own and in no way
RIL attracts any liability for any inconsistency or irregularity in terms of the accuracy
completeness, veracity, or truth of the content of the presentation/publication. In
addition, RIL shall not be liable for any copyright infringement and
misrepresentation for the presented content as the content is presumed in good
faith to be a creation of presenters/authors own mind.
The scope of this presentation/publication is strictly for knowledge sharing
purposes and not necessarily to provide any advice or recommendation to the
audience/readers. Any endorsement, recommendation, suggestion, or advice made
by the presenter/author shall be in his personal capacity and not in professional
capacity as an employee of RIL. Any person acting on such endorsement,
recommendation, suggestion, or advice will himself/herself be responsible for any
injury/damage.
Reliance Industries Ltd., 2016

RIL - BRIEF INTRODUCTION

1966- Establishes Textile mill in Naroda
1977- Public share offering Raised money

from public offerings oversubscribed 7X

1982- Builds fiber/filament plant in Patalganga
1995- Builds Polyolefin plants at Hazira
1997- Builds multi-feed cracker at Hazira
1999- Builds Jamnagar refinery
2002- Acquired IPCL a state run company
2008- Builds JERP refinery at Jamnagar
2009- Begins KG D6 gas production
Dhirubhai H. Ambani
Founder Chairman Reliance Group 2013- Builds PBR/SBR plants at Hazira
2014- Builds PTA plant at Dahej
Reliance Industries Ltd., 2016

2014- Builds PET plant at Dahej

RELIANCE PERFORMANCE
Performance;
(For Year 2014-15)

$ bn

Revenue/turnover

62.2

Exports in refining
product

32.5

EBDIT

6.3

Cash profit

5.1

Net profit

3.8

Segment performance

Oil & gas

Refining

Petrochem

Others

Revenues

11,534

339,890

96,804

5,507

EBDIT

3,181

15,827

8,291

1,250

in Rs (Crore)

Global Indian company

Reliance Industries Ltd., 2016

GROWTH PLANS
Jamnagar
Ethylene

MEG

(Figures in 000 tonnes per

annum)

(Figures in 000 tonnes per

annum)

Dahej
PTA
(Figures in 000 tonnes per
annum)

PET
(Figures in 000 tonnes per
annum)

PE
(Figures in 000 tonnes per
annum)

(Figures in 000 tonnes per

annum)

Hazira

Silvassa

PBR/SBR

PFY/PTY

(Figures in 000 tonnes per

annum)

Major expansion in petrochemicals

What is Good for India, is Good for Reliance

Reliance Industries Ltd., 2016

PX

(Figures in 000 tonnes per

annum)

SUCCESSFUL BACKWARD INTEGRATION FOR FEEDSTOCK

SECURITY IN PET & POLYESTER PRODUCTION

Reliance Industries Ltd., 2016

INTRODUCTION

ABOUT SIMULATION AND MODELLING GROUP: We are a close knit group

headed by Dr. Karuna Potdar. Our work includes extension of Simulation Related help
across all sites of RIL. We prepare models of different Process Units, which are used for
trouble-shooting, de-bottlenecking etc. We are also involved in process development and
we work with different verticals in close conjugation.
SIMULATOR AS TROUBLE-SHOOTING TOOLS: Simulation Tools including
Aspen Plus are good for getting to the root cause or any unprecedented anomalies in the
process units. However it should always be remembered that it is a tool and it is
important to give correct inputs and later correct analysis of the results is required to
enhance its efficiency of usage.
ASPEN PLUS AS A TROUBLE-SHOOTING TOOL: In RIL, ASPEN PLUS is the
most frequently used tool for Simulation and Trouble-shooting. Its user friendly
interface and reliability of the obtained results, makes its use extensive in the
organisation.

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PROBLEMS:
1. VADODARA MANUFACTURING DIVISION,
BUTADIENE PLANT DEGASSER PERFORANCE
REDUCTION ISSUE.
2. PATALGANGA MANUFACTURING DIVISION,
LAB PLANT, PARAFFIN COLUMN
PERFORMANCE REDUCTION ISSUE.

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PROBLEM 1: VMD BUTADIENE PLANT

BUTADIENE FLOW DIAGRAM
Ace tylene
washer

Afte r Washer
RUP

M ain Washer

RLP
C- 24

13-503

V A to
Flare

Degasser

C-22

13-502

13-504

13-505

C4R

M X-C4
Fe ed
Propyne
Column

C- 41

P 33
Degasser fee d
flash drum

C- 45

V-22

K.O. Drum

CC-31
Compressor

V-31

1:3
BD

CIS
Final Column

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PROBLEM 1:
Introduction:
The Degasser column of Butadiene Plant in VMD is a packed column with six
beds.
It is required to maintain solvent quality.
By Design all the Beds had same packing.
In April shutdown some packing were changed.
After start-up column performance deteriorated.
Temperature profile changed and PDI increased

Reliance Industries Ltd., 2016

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PROBLEM 1:
Trouble-shooting using Aspen Plus: Given to the seriousness of purpose a team
started working towards the issue.
Aspen Plus simulations were done both in Equilibrium and in Rate-based models for
the design case.
In the Equilibrium case, the column was modelled as a tray column and Murphree
efficiency was tuned
As this column is an absorber, to have a more realistic approach we did the
simulation in Rate-Based mode and Interfacial Area factor, Mass transfer coefficient
factor and heat transfer coefficient factor were tuned.
However both the models gave very similar results.

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PROBLEM 1:
Trouble-shooting using Aspen Plus: contd..
The same tuned models were used to evaluate the disturbed case.

A considerable reduction in Murphree Efficiency/Mass Transfer coefficient

factors were observed.
Depending on this inference, the column was taken under shutdown.
Heavy fouling was observed in the bottom bed and this was the reason for the
reduction in efficiency in both simulation and plant.

Probably for an operation as polymer/dimer formation prone as this, any seed

which might be seated on the packing beds can result into accelerated polymeric
growth under favorable conditions.
Aspen also indicated the malfunction of some temperature indications which were
rectified.
Reliance Industries Ltd., 2016
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PROBLEM 1: INFERENCE

THE DECISION OF SHUTDOWN AND

CLEANING/REPLACING THE PACKING
MATERIAL OF THE BOTTOM BEDS HELPED
MAINTAINING RELIABLE SOLVENT QUALITY,
WHICH IN TURN IS IMPORTANT FOR UPSTREM
EXTRACTIVE DISTILLATION COLUMNS, TYPICAL
OF BUTADIENE PURIFYING UNITS.

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PROBLEM 2: BLOCK DIAGRAM OF LAB PLANT

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PROBLEM 2:
Introduction:
Paraffin Column is Heart of any Linear Alkyl benzene (LAB) Plant.
It is a packed column operating under vacuum.
The Top product is recycle paraffin & the Bottom product of this Column
is the Final LAB Product of Plant.
After May15 turnaround of LAB Plant, when Plant was started, both the
Top and Bottom Products of this Column were observed out of
specification limits.
No activity was carried out in this Column during the turnaround.

Operation team adjusted reflux, reboiler duty etc but specs could not be
15
met.
Reliance Industries Ltd., 2016

PROBLEM 2:
Trouble-shooting using Aspen Plus:
a. A simulation model of the column was available, tested for design case
and stable operation case.
b. A dedicated team went to site for quick access of operating data.
c. The validated model was used to match the disturbed scenario, tuning
Murphree Efficiency.
d. An incredible reduction of efficiency indicated that some unprecedented
problem had occurred inside the column.
e. Shutdown was taken the following day largely on the basis of simulation
results to inspect the column internals.
f. Certain internals showed deviation from design.
g. These issues were rectified.
h. After start-up column performance was restored.
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PROBLEM 2: INFERENCE

Both Top and Bottom Product of the column were

brought within specifications after shutdown. Finished
LAB Product met the quality of saleable Product.
Reduction in LAB content in recycle paraffin by ~93%
aided in preventing the loss of Rs.14.6 Lacs / Day by
avoiding the loss of high value LAB Product in recycle
paraffin stream, which is a permanent loss.

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Aspen as a trouble-shooting tool :

Aspen Plus has an easy and understandable user interface which makes it a
good tool even if we need instant results like the discussed problem 2.
However it is better to have validated models of process units made, such
that any unwanted situation can be easily evaluated.
The reliability of the results is well explained through the discussed cases.
There is facility of modelling the columns in both Equilibrium and Rate
based approaches and helped cross-checking of Problem 1 results.
The constant help through support website, emails and other modes of
communication with the experts of the Aspen team makes solving issues
easier and quicker, and is highly appreciated.
Reliance Industries Ltd., 2016
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THANK YOU
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