Document Type

Article

Publication Date

Summer 8-1-2026

Abstract

Due to the relatively low volatility (α) of propane and propene components, their separation is one of the most energy-intensive processes in the petrochemical industry. This study evaluates the technical, environmental and thermodynamic performance of a mechanical vapor recompression (MVR) heat pump integrated into a C3 splitter, compared to a conventional steam-heated distillation column. A sensitivity study was conducted using Aspen Plus software at different pressures, reflux ratios (RR) and at turndown operations. According to the results, the MVR system uses a compressor to raise the overhead vapor pressure to 38.7 bar to operate the heater without the need for external steam, achieving optimal thermodynamic performance at a pressure of 18 bar. The system achieved a coefficient of performance (COP) of 6.09 at this design point, resulting in a significant energy saving of 83.56%. As a result, reboiler duty (QR) decreased to 6.93 MW which is about one-sixth of the 42.17 MW required by conventional steamheated distillation column. The MVR system also maintained the purity of propene used in the polymer industry at 99.71% at a RR of 15, while reducing CO2 emissions by 58.3%, saving about 7,048 kg/h. The sensitivity study indicated that the combination of high electrical loads and grid-related emission factors renders operation at low pressures (< 12 bar) environmentally detrimental. This study demonstrates that MVR technology is a reliable, environmentally friendly, and highly effective method for decarbonizing highpurity petrochemical separation processes.

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