Distillation

361 Pages·2014·24.94 MB·English

by  Andrzej Gorak

Distillation:
Equipment
and Processes
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
(cid:1)Zarko Oluji(cid:3)c
Delft University of Technology,
Process & Energy Laboratory,
Leeghwaterstraat 39
NL-2628 CB DELFT
AMSTERDAM(cid:129)BOSTON(cid:129)HEIDELBERG(cid:129)LONDON
NEWYORK(cid:129)OXFORD(cid:129)PARIS(cid:129)SANDIEGO
SANFRANCISCO(cid:129)SINGAPORE(cid:129)SYDNEY(cid:129)TOKYO
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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
and accessible form. Distillation aims at filling this gap by offering a succinct
overview of distillation fundamentals, equipment, and applications. Students,
academics,andpractitionerswillfindinDistillationahelpfulsummaryofpertinent
methodsandtechniquesandwillthusbeabletoquicklyresolveanyproblemsinthe
field ofdistillation.
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,
vii
viii Preface to the Distillation Collection
UCL, Dr Z(cid:1)arko Oluji(cid:3)c, Delft University of Technology, and Dr Hartmut Schoen-
makers,formermemberofBASFSE,Ludwigshafendfortheirknowledgeableinput
andexpertise,unremittingpatience,andcontinuousencouragement.Theinvaluable
editorial assistance of Dipl.-Ing. Johannes Holtbru¨gge during the entire editorial
process isalso greatly acknowledged.
EditorialassistanceofVeraKru¨gerisalsoappreciated.IthanktheElsevierteam
JillCetel,BethCampbellandMohanambalNatarajanfortheirsupportandvaluable
help through thewhole editing process.
Dr Andrzej Go´rak
TUDortmundUniversity
Preface to Distillation: Equipment
and Processes
The book Distillation: Equipment and Processes covers distillation equipment-
and processes-related subjects and consists of 10 chapters. The approach, the
depth, and the extentof subject coveragedepend on the author(s) personalchoice
and affinities and therefore differ from chapter to chapter. Nevertheless all reflect
the state of the art.
Startingchapterdescribesanddiscussesbasictypesandperformancecharacter-
istics of well-established vaporeliquid contacting devices. Specific features and
relative advantages/limitations of common types of trays, random packings, and
structured packings are emphasized to facilitate choices in this respect. In Chapter
2 main types of trays and their layouts are described in a general way addressing
their performance characteristics and all what needs to be considered to ensure
properfunctionofatrayacrossawiderangeofoperatingconditions.Randompack-
ingsaredescribedinChapter3inanelaboratedway,startingwithabriefhistorical
overviewandperformancecharacteristicsofcolumnsequippedwithrandompack-
ings. Main body includes a detailed description of important hydraulics and mass
transfer performance-related parameters as well as background and features of
related design method accounting for performance-deteriorating vapor and liquid
maldistributioneffects. Similar approach butinamoregeneralized andillustrative
way is utilized in Chapter 4, where main performance characteristics and relative
advantagesofconventionalandhigh-performancestructuredpackingsaredescribed
and discussed. Particular attention is paid to initial liquid maldistribution and its
detrimental effects as well as that encountered in columns subject to motion.
A simple method to estimate its extent as well as counteracting measures is dis-
cussed and main benefits of optimal performance illustrated using as examples
important industrial applications. Chapter 5 introduces and discusses equipment
design,columnconfiguration,andoperation-relatedaspectsofthemostsustainable
among distillation technologies, i.e. dividing wall column (DWC), exploring the
potential and prospects for expansion of the application window to four-product
separations.
Separation of mixtures including azeotropes is addressed in chapters 6 and 7.
Chapter 6 is a comprehensiveoverview of advances made in extractivedistillation
that thanks to improvements in technology and selection of entrainers had gained
a revived attention in academia and industry. Azeotropic distillation, as described
in a concise way in Chapter 7 still preserves its position and importance in estab-
lished industrial applications. Chapter 8 is an updated review and systematic and
comprehensive coverage of reactive distillation, i.e. a special type of separation
whereinthedistillationprocessisaccompaniedbychemicalreactions.Fundamental
considerations are followed by discussion of benefits, limitations, modeling
approaches, and design methods as well as hardware aspects, and possibilities for
ix
x Preface to Distillation: Equipment and Processes
coupling with other unit operations to enhance overall performance of green
processes are enlightened including recent research. Chapter 9 discusses the
operatingpressureselectioncriteriaandexplorespressureeffectsonstageandreflux
requirement,distillationprocessingeneral,andtrayedandpackedcolumnshydrau-
lics and efficiency in particular. Finally, Chapter 10 considers issues and describes
a method and practices associated with scale-up of equipment in less-known
distillationapplications.
At the endI would liketo thank all the authors for their contributions.
Dr Z(cid:1)arkoOluji(cid:3)c
Delft Universityof Technology
List of Contributors
Wolfgang Arlt
FAU Erlangen-Nuremberg, Erlangen, Germany
Markus Duss
Sulzer Chemtech AG, Winterthur, Switzerland
Vincent Gerbaud
Universite´ deToulouse,INP,UPS,LGC(LaboratoiredeGe´nieChimique),4alle´e
Emile Monso, F-31432 Toulouse Cedex 04 e France; CNRS, LGC (Laboratoire
de Ge´nie Chimique), F-31432 Toulouse Cedex 04 e France
Bjo¨rn Kaibel
BASF SE, ZOT/O e C 104, Ludwigshafen, Germany
Tobias Keller
Laboratory of Fluid Separations, TU Dortmund University, Dortmund, Germany
(cid:1)
Jerzy Mackowiak
ENVIMAC Engineering GmbH, Oberhausen, Germany; ENVIMAC Polska Sp. z
o.o., Ostro´w Wielkopolski, Poland
(cid:1)
Jan F. Mackowiak
ENVIMAC Engineering GmbH, Oberhausen, Germany; ENVIMAC Polska Sp. z
o.o., Ostro´w Wielkopolski, Poland
(cid:3) (cid:1)
Zarko Olujic
Process and Energy Laboratory, Delft University of Technology, Delft,
The Netherlands
Michael Resetarits
Fractionation Research, Inc., Stillwater, OK, USA
Ivonne Rodriguez-Donis
Instituto Superior de Tecnologı´as y Ciencias Aplicadas (InSTEC). Ave Salvador
Allende y Luaces. La Habana. 10400. Cuba
Hartmut Schoenmakers
Ahornweg, Dossenheim, Germany
Lothar Spiegel
Sulzer Chemtech AG, Winterthur, Switzerland
xi
List of Symbols and Abbreviations
Latin symbols
Symbol Explanation Unit Chapter
A Cross-sectionalarea m2 9
A Activearea m2,ft2 2
a
A Bubblingarea m2 2
b
A Columncross-sectionalarea m2 2,3,9,10
C
A Downcomerarea m2 2,9
DC
A Receivingpanarea m2 2
RP
a Effectivespecificinterfacialarea m2/m3 3,4
e
formasstransfer
a Specificgeometricareaof m2/m3 1,3,4
geo,p
packing
B Drippointspercolumncross 1/m2 3
sectionalarea
B Dimensionlessliquidload – 3
L
b Baselength,width m 4
C,C Constants – 3
i
C Modelparameterfordetermining s(2/3)/m(1/3) 3
B
thepressuredropofanirrigated
packedbedforRe (cid:1)2
L
C VaporloadC-factorbasedon m/s 2
b
bubblingarea
C Modelparameterfordetermining s(2/3)/m(1/3) 3
C
thepressuredropofanirrigated
packedbedforRe <2
L
C Floodingpointconstant – 3
Fl
C Costsofheatingstream V/t 3
H
CNi;E Entrainercapacityfor – 6
componenti
C Liquidcapacityfactor m/s 4,9
L
C Operatingcostsofnormal V/h 3
O
pressurecolumn
C Operatingcostsofvacuum V/h 3
OB
distillationcolumn
C Constantfordeterminingthetotal – 3
P
liquidhold-upofpackings(for
turbulentliquidflow)
(continued)
xiii
xiv List of Symbols and Abbreviations
dcont’d
Symbol Explanation Unit Chapter
C VaporloadC-factorbasedon m/s 2
s
totalcolumncross-sectionalarea
C Vapor/gascapacityfactor m/s 4,9
V
D Molardistillateflowrate kmol/s 6
D Columnsectiondiameter m 9,10,3
C
D Liquiddiffusivity m2/s 3,4
L
D Vapor(gas)diffusivity m2/s 3,4
V
d Nominalpackingdiameter m 3
d Hydraulicdiameterforgasor m 1,3,4
h
vaporflow
d Particlediameter m 3
p
d Tubediameter,inside m 3
R
d Dropletdiameteraccordingto m 3
T
Sauter
E Columnefficiency % 3
C
E Murphreevaportrayefficiency % 2
MV
E Overallcolumnefficiency % 2,9
OC
F Force N 2
F Feedflowrateofcomponenti kmol/s,kg/s 6
i
F Packingfactorofdrypackedbed 1/m 3
P
F VaporloadF-factorbasedon Pa0.5 2
s
totalcolumncross-sectionalarea
F F-factor Pa0.5 2,3,4,9,10
v
F* Floodloadfactor m/s 3
V,FI
g Accelerationduetogravity m/s2 3
H Heightofpackedbed m 3
h Height m 1,4,6
h Liquidhold-up m3/m3 3
L
h0 Liquidhold-upbasedonfree m3/m3 3
L
columnvolume
h Liquidhold-upabovetheloading m3/m3 3
L,S
lineandbelowthefloodingpoint
K Columnwallfactor – 3
K ,K ,K ,K Constants – 3
1 2 3 4
K Distributioncoefficient – 6
i
K Correctionfactorforvapor – 3
rV
density
k Relativegasload – 3
L_;L Molarflowrateofliquid kmol/s 2,3,6
M_L Liquidmassflowrate kg/s 2,3,9,10
M_V Vapor(gas)massflowrate kg/s 2,3,9,10
m Slopeoftheequilibriumline – 3
List of Symbols and Abbreviations xv
dcont’d
Symbol Explanation Unit Chapter
N Numberofactualtrays/stages – 2
a
N_i Molarflowrateofcomponentor mol/s 5,7
streami
N Numberoftheoreticaltrays/ – 2,3,4,10
t
stages
P Distributionparameter 1/m 3
V
p Operatingpressure Pa 3,10
Dp Pressuredrop Pa 3
Dp0 Pressuredropofdrypackedbed Pa 3
p Vaporpressureofpure mmHg,Pa 3,6,7
T
component
p Pressureatthetopofthecolumn Pa 3
T
p Pressureatthebottomofthe Pa 3
W
column
Rb Reboilratio – 6
RR Refluxratio – 2,3,6
S Strippingfactor – 2,3,4
S Extractivesaddlepoint – 6
extr
S Selectivityofcomponentitoward – 6
i/j
componentj
SF Systemfactor – 2
SN Stablenodeoftheextractive – 6
extr
compositionprofilemap
s Sidelength m 1
T Temperature K 3
T Boilingtemperature K 6
b
T Temperatureatthetopofthe K 3
D
column
T Temperatureofheatingmedium K 3
H
T Temperatureofliquidmixturein K 3
W
thebottomofthecolumn
TS TraySpacing m 2
t Time s 4
t Liquidcontacttime s 2
L
t Gascontacttime s 2
V
u Superficialliquidvelocity/specific m/s 3,4,9
L
liquidload
u Superficialvapor(gas)velocity m/s 3,4,9
V
(continued)