Three Phase Distillation

Three Phase Distillation

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Chem 11_1.pdf

Three Phase Distillation

Introduction
In previous modules, we have installed distillation columns design for
two phases. However, these columns will not work for three phase
systems. When dealing with three phase systems, it is necessary to use a
different type of column that uses a different Input Expert, and a
different default solver.
Due to the addition of a second liquid phase in the column, it is very
difficult to model this type of column. For this reason, we must use the
Sparse Continuation Solver to solve these systems.
The three phase system in this example consists of a 2-butanol, water,
n-butyl-acetate system. The feed to the column is saturated liquid at
atmospheric pressure. The liquid product from the condenser is 98%
pure water, and the liquid product from the reboiler is a mixture of the
two other components (2-butanol and n-butyl-acetate).

Learning Objectives
In this module, you will learn:

How to use the three phase distillation column in HYSYS.

When to use the Dynamic Initial Estimate Generator (IEG).
Why the Sparse Continuation Solver must be used to solve
three phase columns.

Prerequisites
Before beginning this module, you should have some experience with
installing distillation columns in HYSYS. Previous experience with
normal two phase systems will help you understand the principals
behind the operation of three phase systems.

Three Phase Distillation

Background
The three phase stream that will be distilled here will consists of three
components: water, n-butyl-acetate, and 2-butanol. The ternary
diagram for these three components at 25 oC (77 oF) and 101.3 kPa (14.9
psia) looks something like this:

This plot was generated using the DISTIL software package produced
by AEA Technology Engineering Software.
The composition of the feed stream is given in the following table:
Component

Mole Fraction

Water

0.35

n-Butyl-Acetate

0.40

2-Butanol

0.25

As you can see (using the ternary graph above), this stream will lie
within the two liquid phase region.

Three Phase Distillation

The Differences Between Two and

Three Phase Distillation
With a normal two phase distillation setup, it would be impossible to
distil the stream described on the previous page. Fortunately, HYSYS is
able to model the distillation of streams like this by using a different
column setup routine.

Different Solvers
With two phase distillation the most common solver that is used is the
"HYSIM Inside-Out" solver. This solver is good for most hydrocarbon
systems, but it can not handle highly non ideal chemical systems,
including three phase systems.
The default solver for three phase columns is the "Sparse
Continuation" solver. This more advanced solver is able to handle three
phase, non ideal chemical systems, that other solvers can not calculate.

Different Input Experts

The second major difference between two and three phase distillation
is the different input experts that each uses. You have already seen the
input expert used by the "normal" two phase distillation column. The
input expert used by the three phase column is similar though slightly
more complex. You will use this interface when we install the three
phase column later in this module.

Different Column Specifications

Finally, the third major difference between the two column types is the
additional column specification that are available when using the three
phase column operation. Due to the complications that a second liquid
phase adds to the column operation, additional specifications are
required to help the column converge.
Despite these apparent differences, setting up columns to handle three
phase streams is not that much more complicated than setting them up
to handle two phase streams.
You already have experience with two phase systems, and you will find
that setting up the three phases system is not that much more
complicated.

Process Overview

Three Phase Distillation

Column PDF

Three Phase Distillation

Building the Simulation

The Basis Environment
In this case, we will use the NRTL Activity model with the UNIFAC VLE
estimated interaction parameters for the unknown binaries.
Begin a new HYSYS case and select the NRTL Activity model as the
Property Package. The three required components are:

Water
2-Butanol
n-B-Acetate
On the Binary Coefficients tab, press the Unknowns Only button.
Enter the Simulation Environment.

The Simulation Environment

Adding the Feed Stream
Create a new stream and define it with the following information:

The mass densities of the

phases can be found on the
Properties page. You will have
to stretch the window in the
horizontal direction in order
to view all the information.

In This Cell...

Enter...

Name

Feed

Vapour Fraction

0.0

Pressure

101.3 kPa (14.9 psia)

Molar Flow

50 kgmole/h (110 lbmole/hr)

Mole Fraction - Water

0.35

Mole Fraction - 2-Butanol

0.25

Mole Fraction - n-B-Acetate

0.40

What is the Mass Density of the Liquid Phase? __________

and the Aqueous Phase? __________
Which phase is the "heavy" phase? ______________

Three Phase Distillation

Adding the Distillation Column

Add a Three Phase Distillation Column operation to the simulation
using one of the available methods.
The Three Phase Distillation
Column icon.

Note: Make sure that you install the Three Phase column operation, not
the two phase one.
As mentioned before, the Input Expert for the Three Phase column is
slightly different than the one used for an ordinary Two Phase column.
For this reason, each page will be shown here.
The input expert for the three-phase distillation column is different
from the input expert that was seen previously. The first page of the
expert allows you to select the type of column that you want to add to
the model. Select the Distillation radio button and press the Next
button.

Three Phase Distillation

On the next page, set the number of stages at 6, and set the "Two Liquid
Phase Check" on the top five stages.

On the third page, enter names for the streams around the condenser.
For this column, the Reflux Stream will be the Lights only; therefore,
select the appropriate radio button in this group box.

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Three Phase Distillation

On the fourth page, set the vapour rate to 0.0 and the Light Reflux
Fraction to 1.0. The degrees of freedom should read 0, once both of
these values are entered.

On the fifth page, attach the Feed stream to stage 1. Also, define the
reboiler energy stream and attach a liquid product stream to the
reboiler. From now on, the screens will look familiar to the input expert
screens that you have seen previously.

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Three Phase Distillation

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On the next page, set the condenser pressure at 101 kPa (14.9 psia), and
the reboiler pressure at 105 kPa (15.5 psia).

On the next page, you are asked to supply optional temperature

estimates. Enter values of 85, 90, and 95 oC (185, 195, and 205 oF) for
the condenser, top stage and reboiler temperature estimates,
respectively.

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Three Phase Distillation

We are now done. Press the Done button to close the input expert. Note
that if the formation of azeotropes were a concern in this column, the
Azeotropic Initialization button would have been pressed, and HYSYS
would have checked for possible azeotropes among the selected
components.
You are automatically placed on the Columns property view; move to
the Monitor page of the Design tab.
How many Degrees of Freedom are shown here? __________
Enter a Bot Prod Rate of 33 kgmole/h (75 lbmole/hr). Press the Run
button to converge the column; the column should start to solve, and
will reach a converged solution quickly. If the column does not solve in
the first attempt, increase the Bot Rate Spec value to 35 kgmole/h
(80 lbmole/hr) and try again. Once the column converges, decrease the
spec back to its original value.

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