Heat integration of fractionating systems in para-xylene plants based on column optimization

In this paper, the optimization of xylene fractionation and disproportionation units in a para-xylene plant is performed through a new method for systematic design based on GCC (grand composite curve) and CGCC (column grand composite curve). The distillation columns are retrofitted by CGCC firstly. Heat Integration between the columns and the background xylene separation process are then explored by GCC. We found that potential retrofits for columns suggested by CGCC provide better possibilities for further Heat Integration. The effectiveness of the retrofits is finally evaluated by means of thermodynamics and economic analysis. The results show that energy consumption of the retrofitted fractionating columns decreases by 7.13 MW. With the improved thermodynamic efficiencies, all columns operate with less energy requirements. Coupled with Heat Integration, the energy input of the para-xylene plant is reduced by 30.90 MW, and the energy outputs are increased by 17 MW and 58 MW for generation of the 3.5 MPa and 2.5 MPa steams. The energy requirement after the Heat Integration is reduced by 12% compared to the original unit. The retrofits required a fixed capital cost of 6268.91 × 103 $ and saved about 24790.74 × 103 $/year worth of steam. The payback time is approximately 0.26 year for the retrofits.