Distillation : operation and applications

452 Pages·2014·29.64 MB·English

by  Andrzej Gorak

Distillation: Operation
and Applications
Edited by
Andrzej Go´rak
Laboratory of Fluid Separations
Department of Biochemical and Chemical Engineering
TU Dortmund University
Emil-Figge-Str. 70
D-44227 Dortmund
Hartmut Schoenmakers
Laboratory of Fluid Separations
Department of Biochemical and Chemical Engineering
TU Dortmund University
Emil-Figge-Str. 70
D-44227 Dortmund
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Preface to the Distillation Collection
For more than 5,000 years distillation has been used as a method for separating
binary and multicomponent liquid mixtures into pure components. Even today, it
belongs to the most commonly applied separation technologies and is used at
such a large scale worldwide that it is responsible for up to 50% of both capital
and operating costs in industrial processes. It moreover absorbs about 50% of the
total process energy used by the chemical and petroleum refining industries every
year.Giventhatthechemicalindustryconsumed19%oftheentireenergyinEurope
(2009),distillation is the bigdriverof overall energyconsumption.
Althoughdistillationisconsideredthemostmatureandbest-understoodsepara-
tion technology, knowledge on its manifold aspects is distributed unevenly among
different textbooks and manuals. Engineers, by contrast, often wish for just one
referencebookinwhichthemostrelevantinformationispresentedinacondensed
andaccessibleform.Distillationaimsatfillingthisgapbyofferingasuccinctover-
viewofdistillationfundamentals,equipment,andapplications.Students,academics,
and practitioners will find in Distillation a helpful summary of pertinent methods
and techniques and will thus be able to quickly resolve any problems in the field
of distillation.
This bookprovidesa comprehensiveand thorough introductioninto all aspects
of distillation, covering distillation history, fundamentals of thermodynamics,
hydrodynamics, mass transfer, energy considerations, conceptual process design,
modeling, optimization and control, different column internals, special cases of
distillation, troubleshooting, and the most important applications in various
industrialbranches, including biotechnologicalprocesses.
Distillation forms part of the “Handbook of Separation Sciences” series and is
available as a paper book and as an e-book, thus catering to the diverging needs
ofdifferentreaders.Itisdividedintothreevolumes:“Fundamentalsandprinciples”
(EditorsA.Go´rakandE.Sorensen),“Equipmentandprocesses”(EditorsA.Go´rak
and Z(cid:1). Oluji(cid:3)c), and “Operation and applications” (Editors A. Go´rak and H.
Schoenmakers). Each volume contains chapters written by individual authors with
acclaimed expertise in their fields. In addition to that, readers will find cross-
references to other chapters, which allow them to gain an extensive overview of
state-of-the-arttechnologiesandvariousresearchperspectives.Helpfulsuggestions
for further reading concludeeach chapter.
Acomprehensiveandcomplexpublicationsuch asDistillationisimpossibleto
complete without the support of an entire team whose enduring help I wish to
acknowledge.Inparticular,Iwishtoexpressmyheartfeltgratitudetothe42leading
worldexpertsfromtheacademiaandindustrywhocontributedtothechaptersofthis
book.Ithanktheco-editorsofthethreevolumesofDistillationdDrEvaSorensen,
UCL, Dr Z(cid:1)arko Oluji(cid:3)c, Delft University of Technology, and Dr Hartmut
vii
viii Preface to the Distillation Collection
Schoenmakers,formermemberofBASFSE,Ludwigshafendfortheirknowledge-
ableinputandexpertise,unremittingpatience,andcontinuousencouragement.The
invaluable editorial assistance of Dipl.-Ing. Johannes Holtbru¨gge during the entire
editorialprocessisalso greatlyacknowledged.
EditorialassistanceofVeraKru¨gerisalsoappreciated.IthanktheElsevierteam
JillCetel,BethCampbellandMohanambalNatarajanfortheirsupportandvaluable
help through thewhole editing process.
Dr Andrzej Go´rak
TUDortmundUniversity
Preface to Distillation: Operation
and Applications
ThisisthelastofthreebooksinaseriescoveringallaspectsofDistillation.Thisbookon
Operation and Applications provides an overview on all operational aspects and
describestechnologiesinvariousapplicationfields.Itconsistsof10chaptersofdifferent
authors.Theapproachtothecontenttogetherwiththechoiceofsubjectsandexamples
are the authors’ choice but the book represents a comprehensive overview on the
operationalprinciplesandthewidespreadapplicationrangeofdistillationingeneral.
In Chapter 1 control and operation principles for columns including coupled
mass and heat integrated configurations and plantwide control are described. The
secondchapterdealswithcolumntroobleshooting.Analysisofdisturbancesisintro-
ducedandmethodstosolvetheproblemsareoutlined.Strategiesforunderstanding
problems in connection with plant operation are given and special investigation
techniques are explained in detail. Chapter 3 is on performance testing techniques
forindustrialscalecolumnswithalltypesofinternals.Instructionsforrunningtests
and proceduresto evaluate the results aregiven.
The following four chapters describe in detail the configurations of distillation
sequences used in different applications. The content of Chapter 4 is distillation
in refining processes. Flowsheets of such processes are explained in detail and the
improvement potentials even for well-established processes are shown including
the choice of special and new column internals. Chapter 5 deals with distillation
in bulk chemicals industry, in which columns of similar dimensions as in refining
processes are used but physical properties of the separated components are quite
different. Consequently new operational challanges like foaming, fouling, and
designproblemsconnectedwithcolumnefficienciesarise.InChapter6theaspects
of distillation in small-scale plants for specialty chemicals that frequently need
low-pressure conditions are discussed. Special aspects are low liquid loads in the
columns, aqueous three phase systems, and reactions that may occur. In Chapter 7
veryspecialapplicationofairdistillationispresented.Thedifferentprocessvariants
at the extreme conditions of pressure and temperature are explained and problems
like maldistributionat the lowliquid loads are adressed.
Inthelastpartofthebookfuturetrendsanddevelopmentsaredescribed.Atfirst
new distillation techniques like high-gravity equipment and microdistillation are
showninChapter8.Chapter9dealswithapplicationofdistillationinbiotechnology,
especiallywithrespecttothedifferentdemandsconnectedwithred,green,andwhite
biotechnology.Thelastchapterexplainstheapplicationofnewseparatingagentslike
ionicliquidsandhyperbranchedpolymers.Examplesaregivenandthemethodsfor
thermodynamicdescriptionoftheseveryspecialsolventsareintroduced.
At the end Iwould like tothank all the authors for their contributions.
Dr Hartmut Schoenmakers
BASF(emeritus)
ix
List of Contributors
Wolfgang Arlt
University Erlangen-Nuremberg, Erlangen, Germany
Tony J. Cai
Fractionation Research, Inc., Stillwater, OK, USA
Stuart Fraser
Consultant. London, UK, Formerly Head of Separations Group, BP Oil
Henry Z. Kister
Fluor Corporation, Aliso Viejo, CA, USA
Hendrik A. Kooijman
Department of Chemical Engineering, Clarkson University, Potsdam,
New York, USA
Koon Fung Lam
Department of Chemical Engineering, UCL, London, UK
Philip Lutze
Department of Biochemical and Chemical Engineering, Laboratory of Fluid
Separations, TU Dortmund University, Dortmund, Germany
William L. Luyben
Department of Chemical Engineering, Lehigh University, Bethlehem, PA, USA
Anton Moll
Engineering Services, Linde Engineering Division, Pullach, Germany
Eva Sørensen
Department of Chemical Engineering, UCL, London, UK
Daniel Sudhoff
Department of Biochemical and Chemical Engineering, TU Dortmund
University, Dortmund, Germany
Ross Taylor
Department of Chemical Engineering, Clarkson University, Potsdam,
New York, USA
Gerit Niggemann
Evonik Industries AG, Hanau/Marl, Germany
Armin Rix
Evonik Industries AG, Hanau/Marl, Germany
Ralf Meier
Evonik Industries AG, Hanau/Marl, Germany
xi
List of Symbols and Abbreviations
Latin Symbols
Symbol Explanation Unit Chapter
A Cross-sectionalarea m2 2,6
A Bubblingarea m2 3
b
A Columncross-sectionalarea m2 3
c
a Specificsurfacearea m2/m3 6
a Relativedowncomerarea m2/m2 5
DC
a Effectivespecialinterfacialareafor m2/m3 7
e
masstransfer
a Specificpackingarea m2/m3 7
P
B Molarbottomsflow-rate kmol/s 1
B Secondvirialcoefficient m3/mol 10
11
Ca Capillarynumber – 7
C Wardtraycapacityfactor m/s 5
BA
C Dischargecoefficient – 5
D
CN CapacityofsolventiinIL – 10
i;IL
C Orificecoefficient – 7
O
C Liquidcapacityfactor m/s 3,5
L
C Vaporcapacityfactor m/s 3,5
V
CV Coefficientofvariation – 3
c Specificheatcapacity HJ/Kg(cid:1)C 2
p
D Overheadmassflowrate Kg/H 2
D Diameter m 2
D Molardistillateflow-rate kmol/s 1
D Columndiameter m 6
C
D Orificediameter m 7
O
d Diameter m 6
d Holediameter m 6,7
h
d Packingdiameter m 5
P
d Sauterdiameter m 6
S
E Energy kJ 6
E Overalltrayefficiency % 3
O
E Overallcolumnefficiency % 3,5
OC
F F-factor Pa0.5 3,7
F Molarfeedflow-rate kmol/s 1
F Packingfactor 1/m 2,5
P
fi Fugacityofcomponenti Pa 10
GE Freeexcessenergy J 10
(Continued) xiii
xiv List of Symbols and Abbreviations
dCont’d
Symbol Explanation Unit Chapter
G Gravitationalacceleration m/s2 6,7
H Enthalpy MJ/kg 2
HE Excessenthalpie J 10
Hi Henryconstant Pa 10
h Height/depth m 2,3,7
h Clearliquidheightonatray m 6,7
cl
h Downcomerbackup m 2,3
DC
h Frothheight m 3
f
h Specificenthalpyofstream/phasei kJ/kg 2,3
i
h Heightofliquid-sidetransferunit m 7
LTU
DhV;ref Vaporenthalpyatthereference kJ/kg 3
point
h Heightofvapor-sidetransferunit m 7
VTU
h Enthalpyofcoolingwater kJ/kg 3
W
I Radiationintensityofthedetector eV 2,3
I Radiationintensityofthesource eV 2,3
0
K Proportionalgain,tuningparameter – 1
C
ofacontroller
Ki Phaseratio – 10
K Ultimategain,tuningparameterofa – 1
U
controller
k Equilibriumfactor – 6
k Liquidmasstransfercoefficient m/s 7
L
k Vapormasstransfercoefficient m/s 7
V
L Liquidflowrate kg/s,kmol/s 3,5,6,7,10
M Massflowrate kg/h 2
M_i Massflowrateofcomponentor kg/s 2,3
streami
N Numberofactualstages/trays – 3
a
N Numberofdrippoints 1/m2 7
drip
N Numberoftheoreticalstages/trays – 3,6
t
N_i Moleflowrateofcomponentor kmol/s 3
streami
n Numberofmoles mol 10
i
P Ultimateperiod s 1
U
p Pressure Pa(bar) 1,6,7,10
pLV Vaporpressureofcomponenti Pa 10
0;i
Dp Pressuredrop Pa 2,3,6,7
Dp Floodpressuredrop,mmwaterper – 2
flood
mofpackingheight
Dp Drytraypressuredrop Pa 6
dt
Q_ Duty WorHW 1,2,3
R Refluxmassflowrate kg/h 2
R Gasconstant J/molk 10
R Molarrefluxflow-rate kmol/s 1
List of Symbols and Abbreviations xv
dCont’d
Symbol Explanation Unit Chapter
RR Refluxratio(ratioofrefluxtodistillate) – 1,4
S Strippingfactor – 3,5,6
S Streamflow-rate kmol/s 1
SE Excessentropy J/K 10
SF SystemFactor – 5
T Absolutetemperature K,((cid:1)C) 1,7,10
T Temperature (cid:1)C 2
DT Temperaturedifference K 6
T Boilingtemperature,boilingpoint K
b
TS TraySpacing m 2,5,6
u Velocity m/s 3,5,7
u Downcomervelocity m/s 2,5
DC
u Holevelocity m/s 7
h
V Vaporflowrate kg/s,kmol/s 3,5,6,7,10
V Retentionvolume m3 10
R
wi Massfraction,weightfractionof kg/kg
componenti
xi Molarfractionofcomponenti,liquid mol/mol 1,3,7,9,10
phase
yi Molarfractionofcomponenti,vapor mol/mol 1,6,10
phase
Greek Symbols
Symbol Explanation Unit Chapter
a Relativevolatility(10->separation – 1,3,5,7,10
factor)
b Separationefficiency – 10
gi Activitycoefficient – 10
ε Porosity(voidfraction) m3/m3 6
h Dynamicviscosity Pas 5,7
q Contactangle (cid:1) 5,7
m Effectivemassabsorptioncoefficient 1/cm 2,3
m absorptioncoefficient m2/kg 2
c thickness m 2
r Density kg/m3 2,3,5,6,7
r Averagedensity kg/m3 3
Dr Densitydifference kg/m3 5
(Continued)
xvi List of Symbols and Abbreviations
dCont’d
Symbol Explanation Unit Chapter
r Waterdensity kg/m3 3
W
s Surfacetension N/m 5,6,7
s Derivativetimeconstantofa s 1
D
controller
s Integratortimeconstantofa s 1
I
controller
f Volumefraction – 3
4 Flowparameter – 5
4i Fugacitycoefficientofcomponenti – 10
j Frothdensity kg/m3 3,6
y Fractionoffreearealeftforvapor – 7
flow
x Drylosscoefficientforcontraction – 7
dry
andexpansion
c Thickness m 2,3
Subscripts
Symbol Explanation Chapter
C Condenser 1,3
L Liquid 2,3,5,6,7
max Maximum,maximal 7
min Minimum,minimal 7
PA Pumparound 2
R Reboiler 1,3
V Vapor 2,3,5,6,7
Abbreviations
Abbreviation Explanation Chapter
AGMD Airgapmembranedistillation 9
AIChE AmericanInstituteofChemical 3,5
Engineers
API Activepharmaceuticalingredients 8
ASU Airseparationunit 6
BAHX Brazedaluminumheatexchanger 6