Optimization of a 100% Product Utilization Process for LPG Separation Based on Distillation-Membrane Technology

TL;DR

This paper optimizes a hybrid distillation-membrane process to efficiently and economically separate LPG into high-purity propane, n-butane, and isobutane.

Contribution

A novel hybrid distillation-membrane process is optimized for full LPG utilization with high economic performance.

Findings

A two-stage membrane system with partial residue-side reflux achieved a total operating cost of 31.58 USD/h.

Optimal membrane parameters included an area of 800 m2, n-butane permeance of 0.9 kg·m−2·h−1, and a separation factor of 40.

The hybrid process ensures high n-alkane recovery while minimizing energy and capital costs.

Abstract

This study presents the techno-economic optimization of a hybrid distillation-membrane process for the complete fractionation of liquefied petroleum gas (LPG), targeting high-purity propane, n-butane, and isobutane recovery. The process employs an initial distillation column to separate propane (99% purity) from a propane-enriched stream, which is subsequently fed to a two-stage membrane system using an MFI zeolite hollow-fiber membrane for n-butane/isobutane separation. Through systematic simulation and sensitivity analysis, different membrane configurations were evaluated. The two-stage process with a partial residue-side reflux configuration demonstrated superior economic performance, achieving a total operating cost of 31.58 USD/h. Key membrane parameters—area, permeance, and separation factor—were optimized to balance separation efficiency with energy consumption and cost. The analysis identified an optimal configuration: a membrane area of 800 m2, an n-butane permeance of 0.9 kg·m−2·h−1, and a separation factor of 40. This setup ensured high n-alkane recovery while effectively minimizing energy use and capital investment. The study concludes that the optimized distillation-membrane hybrid process offers a highly efficient and economically viable strategy for the full utilization of LPG components.

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