Cost-effective retrofit design of a glycol ether plant for enhanced production flexibility

Abstract

A simulation model is developed to estimate the production of four products (Butyl Monoethylene Glycol Ether, Butyl Diethylene Glycol Ether, Butyl Triethylene Glycol ether and Butyl Polyethylene Glycol Ether) in a Glycol Ether Plant, and to predict the amount of utilities consumed by the manufacturing units. To ensure the broad applicability of the developed model, experiments are first conducted to obtain data needed to model the reaction kinetics, which are then used to model the overall process. A thorough comparison between simulation results and operating data of the actual process obtained under various conditions show that the model is reliable and accurate enough to be used for establishing an operating strategy to maximize the overall profit. Major parameters affecting the economic feasibility of the plant are investigated and their contributions to the cost are expressed as a formula.. In addition, their effective ranges are decided in consideration of various constraints. Based on the results, several cost functions are derived to form an adjustable objective function. To demonstrate the usefulness of the simulation and economic models, a case study is conducted to find the most economically feasible retrofitting method design is found based on the conditions that maximize the objective function.