Distillation Operation and Applications PDF

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Distillation: Operation and Applications

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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

AMSTERDAM • BOSTON • HEIDELBERG • LONDON NEW YORK • OXFORD • PARIS • SAN DIEGO SAN FRANCISCO • SINGAPORE • SYDNEY • TOKYO

Academic Press is an imprint of Elsevier

Academic Press is an imprint of Elsevier 32 Jamestown Road, London NW1 7BY, UK 225 Wyman Street, Waltham, MA 02451, USA 525 B Street, Suite 1800, San Diego, CA 92101-4495, USA The Boulevard, Langford Lane, Kidlington, Oxford OX5 1GB, UK Copyright Ó 2014 Elsevier Inc. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means electronic, mechanical, photocopying, recording or otherwise without the prior written permission of the publisher Permissions may be sought directly from Elsevier’s Science & Technology Rights Department in Oxford, UK: phone (+44) (0) 1865 843830; fax (+44) (0) 1865 853333; email: [email protected]. Alternatively you can submit your request online by visiting the Elsevier web site at http://elsevier.com/locate/permissions, and selecting Obtaining permission to use Elsevier material Notice No responsibility is assumed by the publisher for any injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or from any use or operation of any methods, products, instructions or ideas contained in the material herein Library of Congress Cataloging-in-Publication Data Application Submitted British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library ISBN: 978-0-12-386876-3 For information on all Academic Press publications visit our web site at store.elsevier.com This book has been manufactured using Print On Demand technology. Each copy is produced to order and is limited to black ink. The online version of this book will show color figures where appropriate.

Bottom left and top right photographs on cover courtesy of FRI and J. Montz GmbH

Contents Preface to the Distillation Collection...................................................................... vii Preface to Distillation: Operation and Applications ................................................ix List of Contributors...................................................................................................xi List of Symbols and Abbreviations ....................................................................... xiii

CHAPTER 1

Distillation Control............................................... 1 William L. Luyben

CHAPTER 2

Common Techniques for Distillation Troubleshooting................................................. 37 Henry Z. Kister

CHAPTER 3

Column Performance Testing Procedures .......... 103 Tony J. Cai

CHAPTER 4

Distillation in Refining ..................................... 155 Stuart Fraser

CHAPTER 5

Distillation of Bulk Chemicals........................... 191 Hendrik A. Kooijman, Ross Taylor

CHAPTER 6

Air Distillation ................................................. 255 Anton Moll

CHAPTER 7

Distillation of Specialty Chemicals ................... 297 Gerit Niggemann, Armin Rix, Ralf Meier

CHAPTER 8

Distillation in Bioprocessing............................. 337 Philip Lutze

CHAPTER 9

Special Distillation Applications....................... 367 Eva Sørensen, Koon Fung Lam, Daniel Sudhoff

CHAPTER 10

New Separating Agents for Distillation .............. 403 Wolfgang Arlt

Index ......................................................................................................................429

v

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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. Given that the chemical industry consumed 19% of the entire energy in Europe (2009), distillation is the big driver of overall energy consumption. Although distillation is considered the most mature and best-understood separation technology, knowledge on its manifold aspects is distributed unevenly among different textbooks and manuals. Engineers, by contrast, often wish for just one reference book in which the most relevant information is presented in a condensed and accessible form. Distillation aims at filling this gap by offering a succinct overview of distillation fundamentals, equipment, and applications. 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 book provides a comprehensive and thorough introduction into 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 industrial branches, including biotechnological processes. 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 of different readers. It is divided into three volumes: “Fundamentals and principles” (Editors A. Go´rak and E. Sorensen), “Equipment and processes” (Editors A. Go´rak  Olujic), and “Operation and applications” (Editors A. Go´rak and H. and Z. Schoenmakers). Each volume contains chapters written by individual authors with acclaimed expertise in their fields. In addition to that, readers will find crossreferences to other chapters, which allow them to gain an extensive overview of state-of-the-art technologies and various research perspectives. Helpful suggestions for further reading conclude each chapter. A comprehensive and complex publication such as Distillation is impossible to complete without the support of an entire team whose enduring help I wish to acknowledge. In particular, I wish to express my heartfelt gratitude to the 42 leading world experts from the academia and industry who contributed to the chapters of this book. I thank the co-editors of the three volumes of DistillationdDr Eva Sorensen,  UCL, Dr Zarko Olujic, Delft University of Technology, and Dr Hartmut

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Preface to the Distillation Collection

Schoenmakers, former member of BASF SE, Ludwigshafendfor their knowledgeable input and expertise, unremitting patience, and continuous encouragement. The invaluable editorial assistance of Dipl.-Ing. Johannes Holtbru¨gge during the entire editorial process is also greatly acknowledged. Editorial assistance of Vera Kru¨ger is also appreciated. I thank the Elsevier team Jill Cetel, Beth Campbell and Mohanambal Natarajan for their support and valuable help through the whole editing process. Dr Andrzej Go´rak TU Dortmund University

Preface to Distillation: Operation and Applications This is the last of three books in a series covering all aspects of Distillation. This book on Operation and Applications provides an overview on all operational aspects and describes technologies in various application fields. It consists of 10 chapters of different authors. The approach to the content together with the choice of subjects and examples are the authors’ choice but the book represents a comprehensive overview on the operational principles and the wide spread application range of distillation in general. In Chapter 1 control and operation principles for columns including coupled mass and heat integrated configurations and plantwide control are described. The second chapter deals with column troobleshooting. Analysis of disturbances is introduced and methods to solve the problems are outlined. Strategies for understanding problems in connection with plant operation are given and special investigation techniques are explained in detail. Chapter 3 is on performance testing techniques for industrial scale columns with all types of internals. Instructions for running tests and procedures to evaluate the results are given. 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 design problems connected with column efficiencies arise. In Chapter 6 the aspects 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 very special application of air distillation is presented. The different process variants at the extreme conditions of pressure and temperature are explained and problems like maldistribution at the low liquid loads are adressed. In the last part of the book future trends and developments are described. At first new distillation techniques like high-gravity equipment and microdistillation are shown in Chapter 8. Chapter 9 deals with application of distillation in biotechnology, especially with respect to the different demands connected with red, green, and white biotechnology. The last chapter explains the application of new separating agents like ionic liquids and hyperbranched polymers. Examples are given and the methods for thermodynamic description of these very special solvents are introduced. At the end I would like to thank all the authors for their contributions. Dr Hartmut Schoenmakers BASF (emeritus)

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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

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List of Symbols and Abbreviations Latin Symbols Symbol A Ab Ac a aDC ae aP B B11 Ca CBA CD CN i;IL CO CL CV CV cp D D D DC DO d dh dP dS E EO EOC F F FP fi GE

Explanation Cross-sectional area Bubbling area Column cross-sectional area Specific surface area Relative downcomer area Effective special interfacial area for mass transfer Specific packing area Molar bottoms flow-rate Second virial coefficient Capillary number Ward tray capacity factor Discharge coefficient Capacity of solvent i in IL Orifice coefficient Liquid capacity factor Vapor capacity factor Coefficient of variation Specific heat capacity Overhead mass flow rate Diameter Molar distillate flow-rate Column diameter Orifice diameter Diameter Hole diameter Packing diameter Sauter diameter Energy Overall tray efficiency Overall column efficiency F-factor Molar feed flow-rate Packing factor Fugacity of component i Free excess energy

Unit 2

Chapter

m m2 m2 m2/m3 m2/m2 m2/m3

2, 6 3 3 6 5 7

m2/m3 kmol/s m3/mol – m/s – – – m/s m/s – HJ/Kg  C Kg/H m kmol/s m m m m m m kJ % % Pa0.5 kmol/s 1/m Pa J

7 1 10 7 5 5 10 7 3, 5 3, 5 3 2 2 2 1 6 7 6 6, 7 5 6 6 3 3, 5 3, 7 1 2, 5 10 10 (Continued)

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List of Symbols and Abbreviations

dCont’d Symbol

Explanation

Unit

Chapter

G H HE Hi h hcl hDC hf hi hLTU DhV;ref

Gravitational acceleration Enthalpy Excess enthalpie Henry constant Height/depth Clear liquid height on a tray Downcomer backup Froth height Specific enthalpy of stream/phase i Height of liquid-side transfer unit Vapor enthalpy at the reference point Height of vapor-side transfer unit Enthalpy of cooling water Radiation intensity of the detector Radiation intensity of the source Proportional gain, tuning parameter of a controller Phase ratio Ultimate gain, tuning parameter of a controller Equilibrium factor Liquid mass transfer coefficient Vapor mass transfer coefficient Liquid flow rate Mass flow rate Mass flow rate of component or stream i Number of actual stages/trays Number of drip points Number of theoretical stages/trays Mole flow rate of component or stream i Number of moles Ultimate period Pressure Vapor pressure of component i Pressure drop Flood pressure drop, mm water per m of packing height Dry tray pressure drop Duty Reflux mass flow rate Gas constant Molar reflux flow-rate

m/s2 MJ/kg J Pa m m m m kJ/kg m kJ/kg

6, 7 2 10 10 2, 3, 7 6, 7 2, 3 3 2, 3 7 3

m kJ/kg eV eV –

7 3 2, 3 2, 3 1

– –

10 1

– m/s m/s kg/s, kmol/s kg/h kg/s

6 7 7 3, 5, 6, 7, 10 2 2, 3

– 1/m2 – kmol/s

3 7 3, 6 3

mol s Pa (bar) Pa Pa –

10 1 1, 6, 7, 10 10 2, 3, 6, 7 2

Pa W or HW kg/h J/mol k kmol/s

6 1, 2, 3 2 10 1

hVTU hW I I0 KC Ki KU k kL kV L M M_ i Na Ndrip Nt N_ i ni PU p pLV 0;i Dp Dpflood Dpdt Q_ R R R

List of Symbols and Abbreviations

dCont’d Symbol RR S S SE SF T T DT Tb TS u uDC uh V VR wi xi yi

Explanation Reflux ratio (ratio of reflux to distillate) Stripping factor Stream flow-rate Excess entropy System Factor Absolute temperature Temperature Temperature difference Boiling temperature, boiling point Tray Spacing Velocity Downcomer velocity Hole velocity Vapor flow rate Retention volume Mass fraction, weight fraction of component i Molar fraction of component i, liquid phase Molar fraction of component i, vapor phase

Unit – – kmol/s J/K – K, ( C) C K K m m/s m/s m/s kg/s, kmol/s m3 kg/kg

Chapter 1, 4 3, 5, 6 1 10 5 1, 7, 10 2 6

mol/mol

1, 3, 7, 9, 10

mol/mol

1, 6, 10

2, 5, 6 3, 5, 7 2, 5 7 3, 5, 6, 7, 10 10

Greek Symbols Symbol

Explanation

Unit

Chapter

a

Relative volatility (10- > separation factor) Separation efficiency Activity coefficient Porosity (void fraction) Dynamic viscosity Contact angle Effective mass absorption coefficient absorption coefficient thickness Density Average density Density difference

–

1, 3, 5, 7, 10

– – m3/m3 Pa s

10 10 6 5, 7 5, 7 2, 3 2 2 2, 3, 5, 6,7 3 5

b gi ε h q m m c r r Dr



1/cm m2/kg m kg/m3 kg/m3 kg/m3

(Continued)

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List of Symbols and Abbreviations

dCont’d Symbol rW s sD sI f 4 4i j y xdry c

Explanation Water density Surface tension Derivative time constant of a controller Integrator time constant of a controller Volume fraction Flow parameter Fugacity coefficient of component i Froth density Fraction of free area left for vapor flow Dry loss coefficient for contraction and expansion Thickness

Unit kg/m3 N/m s

Chapter 3 5, 6, 7 1

s

1

– – – kg/m3 –

3 5 10 3, 6 7

–

7

m

2, 3

Subscripts Symbol

Explanation

Chapter

C L max min PA R V

Condenser Liquid Maximum, maximal Minimum, minimal Pump around Reboiler Vapor

1, 3 2, 3, 5, 6, 7 7 7 2 1, 3 2, 3, 5, 6,7

Abbreviations Abbreviation

Explanation

Chapter

AGMD AIChE

Air gap membrane distillation American Institute of Chemical Engineers Active pharmaceutical ingredients Air separation unit Brazed aluminum heat exchanger

9 3, 5

API ASU BAHX

8 6 6

List of Symbols and Abbreviations

dCont’d Abbreviation BAIM BIP CAD Capex CAT CC CDU CFD COK CPI CSTR CT DC DCAC DCO DCMD DPD E ECMD EOS EVC FC FCC FI FPL FRI FT GAN GC GOX GPDC HC HCK HCO HDA HETP HP

Explanation Bubble-assisted interphase masstransfer Binary interaction parameter Computer-aided design Capital expenditures Computer-aided tomography Composition controller Crude distillation unit Computational fluid dynamics Cokers Chemical process industries Continuous stirred-tank reactor Chimney tray Downcomer Direct contact air cooler Decant oil (slurry) Direct contact membrane distillation Drip point density Entrainer Enhanced capacity multiple downcomer Equation of state Evaporation cooler Flow controller Fluid catalytic cracker Flow Indicator Flow path length Fractionation research inc. Flow transmitter Gaseous nitrogen Gas chromatography Gaseous oxygen Generalized pressure drop correlation High capacity Hydrocrackers Heavy cycle oil Hydrodealkylation Height equivalent to a theoretical plate High pressure

Chapter 9 5 7 5 2 1 4 3, 7, 9 4 3 2 2 6 4 9 6 10 5 5 6 1, 2 4 2 5 3, 5, 7 1 6 3, 10 6 5 5 4 4 5 3, 5, 6, 7, 9 6 (Continued)

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List of Symbols and Abbreviations

dCont’d Abbreviation HPC HS-GC HSE HTU HyPol IGC IL L LC LCO LDA LDV LIN LiP LOX LP LPC LPG LTU LVGO MHC MTC MUC NMR OPEX PC PFD PFMD PPE RD RR RSO RTCDS RTD RZB SGP SGMD SP SRK SRP

Explanation High pressure column Headspace gas chromatography Health-safety-environmen...