From batch to continuous extractive distillation using thermodynamic insight: class 1.0-2 case B

A systematic feasibility analysis is presented for the separation azeotropic mixtures by batch and continuous extractive distillation. Based on batch feasibility knowledge, batch and continuous separation feasibility is studied under reflux ratio and entrainer flow-rate for the ternary system chloroform-vinyl acetate-butyl acetate, which belongs to the class 1.0-2 separating maximum boiling temperature azeotropes using a heavy entrainer. How information on feasibility of batch mode could be extended to the feasibility of continuous mode is then studied, possible feasible regions are determined by finding the feasible points based on continuous methodology, they show minimum and maximum feed ratio as a function of the reflux, and a lower bound for the reflux ratio. Results are validated by simulation

Extending Batch Extractive Distillation Thermodynamic Feasibility Insights to Continuous for Class 1.0-2 Case A

The feasibility of batch and continuous extractive distillation analysis for the separation azeotropic mixtures is addressed. Based on batch feasibility knowledge, batch and continuous separation feasibility is studied under reflux ratio and entrainer flow-rate for a working example ternary system acetone-chloroform-benzene, which belonging to the 1.0-2 class case (a). Possible feasible regions are determined by finding the feasible points based on continuous methodology, they show minimum and maximum feed ratio as a function of the reflux, and a lower bound for the reflux ratio. Later on, simulations verified the feasibility of calculating results based on theoretical methodolog

Extractive distillation: recent advances in operation strategies

Extractive distillation is one of the efficient techniques for separating azeotropic and low-relativevolatility mixtures in various chemical industries. This paper first provides an overview of thermodynamic insight covering residue curve map analysis, the application of univolatility and unidistribution curves, and thermodynamic feasibility study. The pinch-point analysis method combining bifurcation shortcut presents another branch of study, and several achievements have been realized by the identification of possible product cut under the following key parameters: reflux ratio, reboil ratio, and entrainer-feed flow rate ratio. Process operation policies and strategy concerning batch extractive distillation processes are summarized in four operation steps. Several configurations and technological alternatives can be used when extractive distillation processes take place in a continuous or batch column, depending on the strategy selected for the recycle streams and for the main azeotropic feeds

Extension of thermodynamic insights on batch extractive distillation to continuous operation. 1. Azeotropic mixtures with a heavy entrainer

We have studied the batch and continuous extractive distillation of minimum- and maximum-boiling azeotropic mixtures with a heavy entrainer. These systems exhibit class 1.0-1a and 1.0-2 ternary diagrams, each with two subcases depending on the location of the univolatility line. The feasible product and feasible ranges of the operating parameters reflux ratio (R) and entrainer/feed flow rate ratio for continuous (FE/F) and batch (FE/V) operation were assessed. Class 1.0-1a processes allow the recovery of only one product because of the location of the univolatility line above a minimum value of the entrainer/feed flow rate ratio for both batch and continuous processes. A minimum reflux ratio R also exists. For an identical target purity, the minimum feed ratio is higher for the continuous process than for the batch process, for the continuous process where stricter feasible conditions arise because the composition profile of the stripping section must intersect that of the extractive section. Class 1.0-2 mixtures allow either A or B to be obtained as a product, depending on the feed location. Then, the univolatility line location sets limiting values for either the maximum or minimum of the feed ratio FE/F. Again, the feasible range of operating parameters for the continuous process is smaller than that for the batch process. Entrainer comparison in terms of minimum reflux ratio and minimum entrainer/feed ratio is enabled by the proposed methodology

Energy Evaluation of Ethanol Dehydration with Glycol Mixture as Entrainer

Extractive distillation of ethanol dehydration using glycols as entrainers is proposed. Specifically, ethanol dehydration of an azeotropic mixture in the presence of ethylene glycol + glycerol mixture is evaluated. Simulation is performed and the vapor‐liquid equilibrium of ethanol + water + ethylene glycol + glycerol is predicted with the NRTL model. Minimization of energy consumption in both extractive and regeneration columns is attempted. Optimal operating parameters of the process including glycol concentration in the solvent mixture, main feed, and entrainer feed trays, total number of theoretical trays, and heat supplied to the reboiler are determined in order to achieve a specified distillate purity of 99.9 mol % ethanol

Novel Procedure for Assessment of Feasible Design Parameters of Dividing-Wall Columns: Application to Non-azeotropic Mixtures

Dividing wall columns (DWCs), as a subset of fully thermally coupled distillation systems (FTCDS), is considered as one of most appealing distillation technologies to the chemical industry, because it can bring about substantial reduction in the capital investment, as well as savings in the operating costs. This study targets on how to improve the energy efficiency of DWCs by achieving their well-designed feasible parameters. Two methods are applied to study the effect of liquid and vapor split ratios including a shortcut method and a method of systematic calculations by using differential equation profiles. In the latter approach, differential composition profiles in each column section are obtained by considering feasible key design parameters. The finding of pinch points for each section profiles allowed determining the limiting values of the operating parameters. The intersections of these profiles are used to get well-designed feasible parameters of the liquid and vapor split ratios in an attempt to obtain the desired purities of the top, bottom, and side-stream products. The obtained parameters are validated by rigorous simulations. Three types of case studies involve the separation of hydrocarbons (n-pentane, n-hexane, n-heptane), aromatics (benzene, toluene, p-xylene), and alcohols (ethanol, propanol, butanol)

Conceptual Design of Non-ideal Mixtures Separation with Light Entrainers

A method is proposed to study the separation of minimum-, maximum-boiling azeotropic, and low volatility mixtures with a light entrainer, to investigate feasible regions of the key operating parameters reboil ratio (S) and entrainer - feed flowrate ratio (FE/F) for continuous processes. The thermodynamic topological predictions are carried out for 1.0–2, 1.0–1a, and 0.0–1 Serafimov’s class diagrams. It relies upon the knowledge of residue curve maps, along with the univolatility line, and it enables the prediction of possible products at the bottom of the column and limiting values of FE/F. The profiles of the stripping, extractive, and rectifying sections are calculated by equations considering S and FE/F, and they bring information about the location of singular points and possible composition profile separatrices that could impair process feasibility. Providing specified product composition and recovery, the approximate calculations are compared with rigorous simulations of extractive distillation processes. Separating non-ideal mixtures using a light entrainer provides more opportunities for the case when it is not easy to find an appropriate heavy or intermediate entraine

An Improved Shortcut Design Method of Divided Wall Columns Exemplified by a Liquefied Petroleum Gas Process

Designing a sustainable and economical distillation system is a big global challenge in the industrial chemical field. To address this issue, one of most promising solutions is the so-called dividing wall columns addressed in this work, which not only can cut energy cost but also use limited installation space. An improved shortcut design approach is developed in this work to provide accurate models for each section of dividing wall columns; meanwhile Underwood’s and Gilliland’s equations are employed to determine minimum reflux ratio and total number of stages in different column sections in terms of corresponding design specifications and operating conditions. This proposed approach has been applied to separations of mixtures of hydrocarbons and alcohol with different values on the ease of separation index. To test its effectiveness, the preliminary design parameters obtained through the improved proposed shortcut method are further validated by a rigorous simulation in Aspen HYSYS. Furthermore, the results indicate that this method could provide much more accuracy of average interconnecting stream composition of the prefractionator and main column than those of other methods. In practice, this method has been applied to a case of liquefied petroleum gas (LPG) separation with three targeted products in an industrial liquefied petroleum gas plant. The applications and efficiency of the shortcut method in this study lay a theoretical foundation for designing the separation of ideal mixtures involving dividing wall columns

Entropy flow and energy efficiency analysis of extractive distillation processes with a heavy entrainer

International audienceThe minimization of the entropy production is equivalent to minimizing the work or energy consumption required by a separation process. Sources of entropy creation during the extractive distillation of a minimum- and maximum boiling azeotropic mixture with a heavy entrainer are evaluated at each column stage in accordance with the second law of thermodynamics, and the distribution of entropy flow in different sections of the column is analyzed. Results show that mixing on feed trays and heat exchange in the reboiler and condenser are the main sources of entropy production. The temperature of the main feed and entrainer feed does not significantly affect the irreversibility of the process at the reference temperature of all flows. Although optimal values can be proposed to achieve a minimum isothermal work, the energy loss of the real process steadily increases with increases in the entrainer/feed flow rate ratio and reflux. The influence of the feed tray shows that product purity tends to vary inversely with energy loss