Objective
To superheat (by + 33 deg.C) the cyclohexane vapour (by re-pressurisation) from the head of a distillation column and re-use it as heating fluid for the column's boilers, saving energy in the form of 6 Bar steam at 34.6 t/h.
During the trial period (1.2.85 to 31.1.86) the following data were recorded on a daily basis:
- the number of hours the cyclohexanol unit was in production;
- the number of hours the heat pump was in operation;
- the number of hours the unit was not in operation;
- all operational parameters determining the heat pump's energy balance.
Problems (causing a three-month delay) arose mainly with the compressor, eg:
-during nitrogen tests, the stator rotor seized, necessitating alterations to the compressor;
- during cyclohexane tests, a leak was found which required further internal sealing;
- during production, seizing between rotor and stator meant the dismantling of the front part of the rotor for checking and repairs.
During operation, the anti-pumping exchanger had to be repaired several times and after repeated tube ruptures (due to vibrations induced by the gas, when the compressor functioned on its anti-pumping circuit) and was replaced by an improved one.
Despite a loss in the expected number of operating hours, a considerable energy saving was achieved ie. 4,264 TOE for 5,685 hours (0.75 TOE/h in comparison with the forecasted 1.067 TOE/h or 7,470 TOE/y for 7,000 operating hours).
The compressor absorbs a little more energy than planned and in order to reach correct compression ratio and slightly reduced boiler surface, a wheel of larger diameter than in the design study was used. In addition, the column itself no longer operates in exactly the same conditions as in the initial project. For process reasons, certain adjustments had to be made (eg. alteration of the head reflux) which slightly reduced the cost effectiveness of the heat pump, through improving the overall process.
The project has been successful.
Joint Venture: Rhone Poulenc chimie
Monsieur GUILLON
25, quai Paul Doumer
FR - 92408 Courbevoie
At the Olone 4 plant, where vapour is mechanically compressed cyclohexane is oxidized into cyclohexanol-cyclohexanone. In the process used the reaction products are diluted in a large volume of cyclohexane. Separation is by distillation and the cyclohexane collected at the top of the column is recycled.
Distillation is carried out between 105 deg. C at the bottom and 90 deg. C at the top of a column.
In the original installation this column was heated by two 340 m2 reboilers fed by 6 bar vapour from high-pressure boilers burning fuel oil and gas expanded through a turbo-alternator.
The condensation heat from the cyclohexane at the top of the column was discharged by an aerocondenser.
In the new installation the cyclohexane vapours leaving the column at 90 deg. C under 1.3 bar are compressed to 3 bars and directed after desuper-heating to three reboilers, each with a capacity of 1 100 m2, where they are condensed. The condensates are then redirected back to the original circuits after the vapours feeding the compressor have been preheated. The old water vapour-heated reboilers have been kept and are used for start-up and are triggered automatically, as is the aerocondenser, when the compressor shuts down. This design technology allows dual-energy operating should there be a need.
The compressor supplied by ALSTHOM ATLANTIQUE is of the centrifugal, monowheel type with multiplier and suction vents.
Flow : 80,000 m3/h
Rotation speed : 3,500 tpm
Blade diameter : 2,5 m
Wheel diameter : 1,25 m
Maximum power : 4 200 kW
Drive motor : 4,500 kW - 1,500 rpm.
The entire installation, reboilers, ancillary exchangers and compressor are in stainless steel because of the presence of formic acid in the cyclohexane vapours.
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Coordinator
92408 Courbevoie
France
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