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Engineering Department , Union Carbide Chemicals and Plastics , P.O. Box 8361, South
Charleston, WV, 25303
Published online: 24 Apr 2007.
To cite this article: J.C. WANG (1980) FIBONACCI SEARCH FOR OPTIMAL FEED LOCATION, Chemical Engineering
Communications, 4:6, 651-663, DOI: 10.1080/00986448008935937
To link to this article: http://dx.doi.org/10.1080/00986448008935937
<!l Gordon
INTRODUCTION
Feed location is an important factor in the design of a new distillation column or in
evaluating the performance of an existing column. A mislocated feed not only can
seriously impair separation efficiency but also affect the energy consumption. The
subject of optimal feed location has been studied by many investigators. McCabe and
Thiele,' Gilliland,' and others define the optimum feed stage based on matching the
ratio of the light and heavy key components in the feed and on the feed stage. Scheibel
and Montross," Floyd and Hipkin;' and Maas,' have developed procedures to find the
optimum feed stage that produces the maximum separations. Shipman!' gave a
criterion of the optimal feed stage based on the minimization of the entropy
production. Although his approach is thermodynamically sound, the method is
difficult to apply and has not much practical value. Recently, Waller and Gustafsson"
treated the feed stage problem in their optimization of the steady state distiIJation
operation.
Distillation processes are the most energy intensive operation in the petroleum and
petrochemical industries. Prengle, et at," reported that up to 40% of the energy
consumed in a petrochemical plant is taken by the distillation columns. It is therefore
more logical to define the optimal feed location based on the energy consumption.
Luyben" has given such a criterion by stating "The minimum energy consumption is
achieved in a column with a fixed number of total trays when not only X D and X B are
held at their specified values but also the feed is introduced onto the optimum feed
"Dr. Wang is now with Simulation Science, Inc., 1400 N. Harbor Blvd., Fullerton, CA 92635.
652
J.C. WANG
tray." In this paper we shall show that the energy consumption of a distillation column
with a fixed number of stages for a specified separation is an unimodal function or the
feed stage location. This function can be evaluated by using a steady state computer
simulation program. The problem of finding the optimal feed location is then to search
for the minimum point of this function. A Fibonacci search procedure is then
developed for solving this problem. The procedure is simple and can be readily
incorporated into any distillation simulation program.
PHYSICAL PROPERTY
INPUT DATA FORMS
PHYSICAL PROPERTY
DATASET (PP-COMMON)
~(DATA
BANK
-.
-..
THERMODYNAMICS
SUBPROGRAMS
COLUMN INITIATION
SUBPROGRAMS
MATHEMATICAL
SUBPROGRAMS
Ul
...J
IJJ
8~
--
~
~
z
~
0::
IJJ
J:
GFLASH
DSTLBT
XFLASH
DSTLSR
SHTCUT
DSTLWH
Ul
\PES
IIIz
PROCESS FLOWSHEET
I-
SEPARATION SUBPROGRAMS
653
MMSP
!i
>
Ul
Ul
tl
o0::
J:
D.
~I
PRINTER
OUTPUT
FIGURE I
PROBLEMSL
OR PROP. \
FILES
III
z
-c
J:
t
TRAY DESIGN PROGRAM
APT~ALL PURPOSE TRAY
interstage heaters (or coolers). The mixture to be separated can be of any degree of
nonideality ranging from those obeying Raoult's law to highly non ideal systems such
as azeotropes. We have incorporated in our Thermodynamics Subprogram Library a
spectrum of equilibrium models. These include Chao-Seader correlation, RobinsonChao correlation, Poynting correction, and others for liquid phase fugacity; RedlichKister, Regulat Solution, NRTL, Wilson equation, Margules, and Uniquac for liquid
activity coefficients; Redlich-Kwong, Second Virial, Prausnitz-Chueh modified
654
J.C. WANG
the absolute value of the difference between the key components ratio in the feed
and that on the feed stage, i.e.,
655
the sum of the absolute values of the difference between the feed composition and
the feed stage composition for all the components.
where Z - feed composition, m.f.; X ~ feed stage composition, m.f. Subscripts i for the
ith component, lk for the light key, hk for the heavy key.
J.e. WANG
656
p= 101
KPA
___3
--~----
16
-------
364 K
[
FIGURE 2 The sample problem.
~ItKGMoL.ES/ HR
657
~ t--\-\--4--1~-4-+--------4-----.----+-------+---+--+~I_+__I_l
5.5
0
i0(=
0 5 4 t--++t-~-;-...
0(
III
0::
J: 5 3
3.7
t----+-ll----++
II:
III
II:
III
~ 5 2 r----tt-\--~-I--__+
3.6 0
lD
III
III
3.5
~ 5. 1 r--~t-\--t__-_":~-I__~r__-
0::
c
~ 5.0 +-+----11--+-++
II:
III
:! 4. 9 -t--+--I--l-1~
o
lD
III
0:: 4. 8
1.8
r---\f--\.~
III
0:: 1.6
1.2 4.6
II:
III
~ 1.0 4.5
c
~ 0.8
i=o(
0::
t ,5
::I
4.4
1.4
0::
i.a
II.
III
0(
l:t:
~ 0
:iC
1.7
06
~ 0.4
z
o
E
0.2
rJl
o
13 0.0
29
28
27
NUMBER
FIGURE 3
J.e. WANG
658
1 = s,
Downloaded by [University of Sydney] at 05:20 30 December 2014
lk
-I (Zlk)
Zhk - (Xhk ) I,
X
1- I: I z, -
(X;)iF I,
(1)
ir
(2)
1-
R/ D,
(3)
1~
V/ B,
(4)
1 ~ Qc>
1=
(5)
(6)
Step I
Supply the input data for the column simulation except the feed stage location. The
data requirements are outlined in the previous section. Also specify the function to be
minimized.
Step 2
Specify the section of the column to be searched by giving the stage number J F, near
the column top and the stage number J F b near the bottom. The difference between J F b
and J F, must be a Fibonacci number F. Then find the number of function evaluations
n corresponding to F. from the table of Fibonacci number (Table I).
Step 3
Determine the first two stage numbers to be checked as follows:
JF, - JF,
+ F._ 2
659
TABLE I
The First 14 Fibonacci Numbers
F,
0
I
2
3
4
5
1
I
2
3
5
8
13
21
34
55
89
144
233
377
6
7
8
9
10
11
12
13
Step 4
Evaluate the function to be minimized as I, and 12 corresponding to the feed stage
numbers JF, and JF 2 by performing the column simulation with the purity specifications for the top and bottom product streams. Also set the search number I - 2.
Step 5
Checkj; vs./2' If II </2, go to Step 6, otherwise set:
Step 6
Set
J.C. WANG
660
and evaluate a new
simulation.
/1
Step 7
Update the search counter I as
I + I
Step 8
Cheek I vs. n. If I = n stop the iteration and go to output. Otherwise repeat Step 5
through Step 8.
This procedure has been programmed into the MMSP program as the fBSRCH
subprogram. The results from all the column simulations are stored and printed in the
final output along with the column profiles corresponding to the optimal feed stage
location. These results including ~b ~C> reflux ratio, reboiler rate, condenser duty,
reboiler duty, number of iterations used in the column simulation, and the convergence
of the column simulations are printed in tabular form.
JF,
+ Fn_ ,
16
+ 5 = 21
JF 2
J F,
+ Fn_ I
16
+ 8 - 24
Column simulations (using DSTLBT) were performed with these two feed stages. The
corresponding reboiler duties were obtained as:
f, - 4.7702 GJ/hr
/2 =
4.5997 GJ/hr
Since f, > /" the minimum point must lie in the section between stage 21 to stage
29. Therefore we eliminated the section from stage 16 to stage 21 from further
consideration. We then followed Step 5 to set the top limit of the new section as JF, -
661
5.9
5.8
1\
5.7
5.6
5.5
5.4
\
\
\
\
--_.
i
1-
-_..-.- --._._-
I
II
-- f--+-
--- -
5.3
~5.2
i
i
1\
!;(
\ !
\
Q
~
.J
lJJ
.. / 1/
It:
It:
I-
g 4.7
lJJ
.It:
i:
1\
4. 8
4. 6
r,,~
SECOND
4. 5 -ELIMINATION
JF.
4. 4
4 3
(JF.i 29
'"'
'
28
26
27
FIGURE 4
..
1!"IRST ELIMINATION _
JF,
JFz JF.
(MIN)
24
25
FEED
23
22
STAGE
21
20
19
18
NUMBER
JF, - 21. We also setf! - f2 - 4.5997 GJ/hr, and JF, - JF2 ~ 24. A new JF2 was
obtained as
JF2
JFt
+ JFb -
JF,
21
29 - 24 - 26
Another column simulation with feed stage at 26 was performed. The reboiler duty
was obtained as
f,
4.7046 GJ /hr
Since f, < f2' the optimal feed location must lie above stage 26. The column section
between stage 26 and stage 29 was eliminated from further consideration. Following
Step 6, we set JFb - 26'/2 ~ f, - 4.5997 GJ/hr, and JF2 - JF, ~ 24. A new JF, was
obtained as
J.e. WANG
662
JF I
JF,
+ JFb
+ 26 - 24
23
II -
JF, - 21
4.6242 GJ/hr
Since f > I,. the minimum point must lie in the section from stage 24 to stage 26. The
section to be searched was finally reduced to three stages. The reboiler duties
corresponding to two of these stages as feed stage (24 and 26) were already obtained.
The final column simulation performed with feed stage J F I - 25 yielded a reboiler
duty II = 4.6168 GJ /hr. This was larger than the reboiler duty (I, ~ 4.5997) obtained
for feed stage J F, = 24. Therefore the optimal feed location was found to be stage 24
from the top.
Table II lists the results obtained from the MMSP program for the above search
procedure. The total number of column simulations used in this search procedure was
5 as compared to 13 used in the case study. In Table III we compared the computer
times used and the computer costs for these two procedures. An IBM 370/168
computer was used for the simulations. The advantage of using the Fibonacci Search
procedure becomes more obvious when larger numbers of stages are in the section to
be searched.
TABLE II
Results of Fibonacci Search Applied to the Sample Problem
Feed
Stage No.
a,
a,
Reflux
Ratio
Boilup
Ratio
Condenser Duty
GJjhr
Reboiler Duty
GJjhr
2\
26
23
25
24
0.31\6
0.6\80
0.0695
0.3422
0.\088
0.\024
0.\789
0.0610
0.0986
0.0589
1.4771
1.4417
1.3983
1.3942
\.3838
3.5292
3.48\4
3.42\ 0
3.4156
3.40\3
4.6349
4.5703
4.4887
4.4818
4.4625
4.7702
4.7056
4.6242
4.6\68
4.5977
TABLE III
Comparison Between Fibonacci Search and Case Study
Fibonacci
Search
No. of Column Simulations
Case Study
\3
20
50
3.27
8.78
4.36
20.00
663
CONCLUSION
A computational procedure using the Fibonacci search technique has been developed
for the location of the optimal feed stage within a section of the column such that the
minimum energy consumption of the distillation column can be achieved. The
procedure is simple and can be readily incorporated into any rigorous distillation
simulation module. This procedure has been used in Union Carbide for relocation of
the feed stage in many existing columns. During 1978 over 25,000 column simulations
have been performed by use of the MMSP computer program. Eight percent of these
simulations used the Fibonacci search procedure for optimal feed location. Most of
them were for feed stage relocation in existing distillation columns to reduce energy
consumption in the plants. The saving of energy cost was estimated to be over a million
dollars per year.
LITERATURE CITED
I. Beveridge, G.S.G .. and Schechter, R.S., Optimization Theory and Practice. McGraw-Hili Book Co..
1970.
2. Chao, K.C .. and Seader, J.D., "A General Correlation of Vapor-Liquid Equilibrium in Hydrocarbon
Mixtures," A./.Ch.E. Journal, 1,598 (1961).
3. Floyd, E.R., and Hipkin, H.G., "Locating Feed Trays in Fractionators," Ind. Eng. Chem., 55 (6), 34
(1963).
.
4. Gilliland, E.R .. "Multicomponent Rectification-Optimum Feed Plate Composition," Ind. Eng.
Chern.. 32, 918 (1940).
5. Himmelblau. D.M., Applied Nonlinear Programming, McGraw-Hili Book Co., 1972.
6. Luyben, W.L., "Steady-State Energy Conservation Aspects of Distillation Control System Design,"
Ind. Eng. Chem. Fundamentals, 14 (4), 321 (1975).
7. Maas, J.H., "Optimum Feed Stage Location in Multicomponent Distillations," Chern. Eng., April 16,
1973, page 96.
8. McCabe, W.L., and Thiele, E.W., Ind. Eng. Chem., 17,605 (1925).
9. Naphtali, L.M., and Sandholm, D.P., "Multicomponent Separation Calculation by Linearization,"
A./.Ch.E. Journal, 17 (1),148 (1971).
10. Prengle, H.W., Crump, J.R., Fang, e.S., Frupa, M., Henley, J., and Worley, T., "Potential for Energy
Conservation of Industrial Operation in Texas," Final Report on Project SID-10, Governor's Energy
Advisory Council, The State of Texas (1974).
II. Scheibel, E.G., and Montross, C.F., "Optimum Feed Tray in Multicomponent Distillation Calculations," Ind. Eng. Chem .. 401 (8), 1398 (1948).
12. Shipman, e.W., "On the Optimum Choice of Feed Stage in Staged Equilibrium Processes," A.I.Ch.E.
Journal, 18 (6),1253 (1972).
13. Sujata, A.D., "Absorber-Stripper Calculation Made Easier," Hydrocarbon Processing and Pet. Ref.
40 (12),137 (1961).
14. Tang, Y.P., "Multicomponent Distillation Calculation by Newton's Method," Union Carbide Chemicals and rlastics. Engineering Department Report. June 7,1972.
15. Union Carbide Chemicals and Plastics, "User's Manual for the Integrated Process Engineering
System," 1976.
16. Waller, K.V., and Gustafsson, T.K., "On Optimal Steady-State Operation in Distillation," Ind. Eng.
Chern. Process Des. Dev., 17 (3), 313 (1978).
17. Wang, J.e. and Henke, G.E., "Tridiagonal Matrix for Distillation," Hydrocarbon Processing," 45 (8),
155 (1966).
.
18. Wang, J.e., "User's Manual for Simulation of Multicomponent Multistage Separatian Processes,"
Union Carbide Chemicals and Plastics, Engineering Department, 1977.
19. Wilde, DJ., "Optimum Seeking Method," Prentice Hall, Inc., Englewood, N.J., 1964.
20. VanWinkle, M., and Todd, W.G., "Optimum Fractionator Design by Simple Graphical Methods,"
Chern. Eng.. September 20,1971, pp. 136-148.
21. Yen, L.e., and Alexander, R.E., "Estimation of Vapor and Liquid Enthalpies," A.I.Ch.E. Journal. II
(2),334 (1965).