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

Design and control of pressure‐swing distillation for separating ternary systems with three binary minimum azeotropes

The separation of ternary nonideal systems with multi‐azeotrope is very important because they are often found in the waste of chemical and pharmaceutical industries, which is much more difficult due to the formation of multi‐azeotrope and distillation boundary. We propose a systematic procedure for design and control of a triple‐column pressure‐swing distillation for separating ternary systems with three binary minimum azeotropes. This procedure involves thermodynamic insights, a two‐step optimization method, and effective control strategy. The separation of tetrahydrofuran (THF)/ethanol/water is used to illustrate the capability of the proposed procedure. It is found that the pressure limits in columns can be determined through the analysis of residue curve maps, distillation boundary, and isovolatility curves. The optimal triple‐column pressure‐swing distillation is generated with the minimum total annual cost (TAC) of $2.181 × 106 in sequence A. The operating conditions are well controlled approaching their desired specifications in an acceptable time when disturbances occur

Intensification and performance assessment for synthesis of 2-methoxy-2-methyl-heptane through the combined use of different pressure thermally coupled reactive distillation and heat integration technique

2-methoxy-2-methyl-heptane (MMH) plays a key role in reformulated gasoline industry due to fewer environmental impacts than methyl tert-butyl ether. Thus, the design of MMH production process has received substantial attention. In this work, we propose a different pressure thermally coupled reactive distillation (DPTCRD) process for the synthesis of MMH aiming at reducing in energy requirements and improvement in environmental benefits. The key design variables are optimized to evaluate the economic feasibility of designed process. Furthermore, the heat integration strategy has been further explored by the application of heat exchanger network based on the observation of the temperature-enthalpy diagram to fully utilize the redundant duty in DPTCRD system. The results demonstrate that the total annual cost of the heat integration-DPTCRD (HI-DPTCRD) is reduced by 29.17% than that of conventional reactive distillation process. In addition, CO2 emission of the proposed HI-DPTCRD is decreased by 75.04% compared with that through the existing process