Distillation Process Package Factory

Integrated Distillation Process Package Factory Solutions by Wangdu (Hebei) Chemical Engineering Co., LTD

Introduction
The industrial distillation process represents a fundamental separation technology widely implemented across the chemical, petrochemical, and pharmaceutical sectors. As a mature yet continuously evolving technology, distillation system efficiency depends significantly on integrated engineering design, precise equipment fabrication, and systematic process integration. Wangdu (Hebei) Chemical Engineering Co., LTD provides comprehensive distillation process package solutions through integrated factory capabilities, encompassing process design, equipment fabrication, and system optimization. This article details the technical framework and operational methodology of our distillation process package factory, supported by engineering data and industry standards.

Factory Capabilities and Technical Infrastructure
Our manufacturing facility spans 24,000 square meters with dedicated workshops for pressure vessel fabrication, column internal assembly, and heat exchanger production. The factory maintains ASME "U" and "R" stamp certifications along with ISO 9001:2015 quality management system certification. The technical infrastructure includes:

• CNC machining centers with positioning accuracy of ±0.05mm

• Automated welding systems employing submerged arc welding (SAW) and gas tungsten arc welding (GTAW)

• Non-destructive testing equipment including digital radiography and ultrasonic flaw detection

• Dimensional verification systems using laser trackers with measurement uncertainty of ±0.025mm

Process Design and Engineering Integration
The foundation of our distillation packages begins with rigorous process simulation and engineering design:

Computational Modeling and Simulation
Our engineering team utilizes Aspen HYSYS and Aspen Plus for process simulation, incorporating thermodynamic packages appropriate for specific chemical systems. For non-ideal mixtures, we employ activity coefficient models (UNIQUAC, NRTL) validated against experimental data. A case study involving isopropanol-water separation demonstrated model predictions within 2.3% of actual plant performance data.

Equipment Design Methodology
Distillation column design follows a systematic approach:

• Vessel sizing based on vapor velocity calculations and flood point analysis

• Tray design incorporating weir loading, downcomer backup, and pressure drop calculations

• Packed column design utilizing mass transfer data and HETP values from packing manufacturers

For a depropanizer column processing 25,000 BPD of natural gas liquids, our design achieved a measured separation efficiency of 98.7% for key components while maintaining a pressure drop of 0.25 psi per theoretical stage.

Fabrication and Quality Assurance Processes
The manufacturing process implements stringent quality control throughout production:

Material Selection and Verification
Materials are selected based on process conditions and compatibility:

• Carbon steel (SA-516 Gr. 70) for hydrocarbon services to -20°F

• Stainless steel (304/316L) for corrosive services

• Clad materials (SA-265) for high-pressure corrosive applications

Material certificates are verified against ASTM specifications, with additional chemical analysis and mechanical testing conducted on 15% of material lots.

Fabrication Procedures
Distillation column fabrication follows established procedures:

• Plate rolling with dimensional tolerance monitoring

• Longitudinal and circumferential welding per ASME Section IX

• Post-weld heat treatment following prescribed temperature curves

• Internal attachment installation with alignment verification

For tray installation, we maintain levelness tolerances of ±1.5mm across column diameters, with measured installation accuracy consistently within ±0.8mm.

Heat Integration and Energy Optimization
Our distillation packages emphasize energy efficiency through systematic heat integration:

Pinch Analysis Implementation
Using pinch technology, we identify energy recovery opportunities. In a benzene-toluene separation project, heat integration between column condensers and reboilers reduced steam consumption by 22% compared to conventional designs, with a calculated payback period of 2.8 years.

Heat Exchanger Network Design
We optimize heat exchanger networks using mathematical programming approaches, achieving approach temperatures of 8-12°C in optimized networks. For a crude distillation unit preheat train retrofit, our design improved heat recovery by 17% while maintaining pressure drop constraints.

Control Systems and Automation
Distillation column control strategies are tailored to process requirements:

Basic Regulatory Control
Standard control configurations include:

• Pressure-compensated temperature control for product quality

• Floating pressure control to minimize energy usage

• Model predictive control for constrained multivariable processes

Implementation of advanced process control on a xylene splitter column demonstrated a 3.2% reduction in energy consumption while maintaining product specifications during feed composition disturbances.

Performance Validation and Testing
Before shipment, critical components undergo functional testing:

Tray Hydraulic Testing
Full-scale tray sections are tested for:

• Hydraulic performance across turndown ratios

• Seal pan effectiveness

• Downcomer backup verification

Testing data confirms operation at 40% of flood point at minimum design rates and 82% at maximum capacity.

Case Study: Solvent Recovery Unit
A recent project involved a methyl ethyl ketone (MEK) recovery system for a synthetic resin plant:

• Design capacity: 5,000 kg/h of 15% MEK-water feed

• Product specification: 99.5% MEK purity

• Energy consumption: 1.8 kg steam/kg MEK recovered

• Project timeline: 8 months from design to commissioning

The system achieved all design parameters with measured energy consumption of 1.76 kg steam/kg MEK during performance testing.

Conclusion
Wangdu (Hebei) Chemical Engineering Co., LTD delivers integrated distillation process packages through coordinated engineering design and factory fabrication. Our methodology combines theoretical process design with practical manufacturing expertise, resulting in distillation systems that meet specified performance criteria with demonstrated reliability. The integrated factory approach provides clients with a single-source solution from conceptual design to equipment supply, ensuring consistency between design intent and delivered equipment.

References

1. Kister, H. Z. (1992). Distillation Design. McGraw-Hill.

2. Lieberman, N. P. (2018). Process Design for Reliable Operations. Gulf Professional Publishing.

3. American Society of Mechanical Engineers. (2021). ASME Boiler and Pressure Vessel Code, Section VIII, Division 1.

4. American Petroleum Institute. (2017). *API Standard 661: Air-Cooled Heat Exchangers for General Refinery Service*.

5. Biegler, L. T., Grossmann, I. E., & Westerberg, A. W. (1997). Systematic Methods of Chemical Process Design. Prentice Hall.

6. Huang, K., & Wang, S. J. (2019). "Energy-Saving Methodology for Distillation System Design." Chemical Engineering Research and Design, 142, 62-73.

7. International Organization for Standardization. (2015). ISO 9001:2015 Quality Management Systems.

8. Towler, G. P., & Sinnott, R. K. (2013). Chemical Engineering Design: Principles, Practice and Economics of Plant and Process Design. Butterworth-Heinemann.