EP426
Chemical Process Design and Optimization
Chapter 3a - Separation train synthesis.
Jan – Apr 2017
Steps in Process Design and Retrofit
Assess Primitive
Problem
Detailed Process Plant-wide
Synthesis - Development of Controllability
Algorithmic Base-case Assessment
Methods
SECTION B
Detailed Design,
Equipment sizing, Cap.
Cost Estimation,
Profitability Analysis,
Optimization
Section B: Algorithmic Methods
Introduction
• Almost all chemical processes require the
separation of chemical species (components):
• To purify a reactor feed
• To recover unreacted species for recycle to a reactor
• To separate and purify the products from a reactor
• Frequently, the major investment and operating
costs of a process will be those costs associated with
the separation equipment
Separation is Energy Intensive
• Separation of a mixture requires an expenditure of
some form of energy.
• Four common industrial techniques:
• the creation by heat transfer, shaft work, or pressure
reduction of a second phase that is immiscible with the
feed phase (ESA – energy separating agent)
• the introduction into the system of a second fluid phase
(MSA – mass separating agent). This must be
subsequently removed.
• the addition of a solid phase upon which adsorption can
occur
• the placement of a membrane barrier
Development of a separation process
It requires the selection of:
1. Methods & Equipment
2. Separation Factor (Energy or Mass Agent )
3. Optimal arrangement (Sequencing)
4. Operating parameters (Temp. & Pressure)
1. Selection of separation method &
equipment
Largely depends of feed condition:
• Vapor: partial condensation, distillation,
absorption, adsorption, gas permeation
(membranes)
• Liquid: distillation, stripping, LL extraction,
supercritical extraction, crystallization, adsorption,
and dialysis or reverse osmosis (membranes)
• Solid: if wet drying, if dry leaching
Common Industrial Separation Methods
Separation Phase of Separation Developed or Separation
Method the feed agent added phase principle
Equilibrium L and/or V Pressure V or L difference
reduction or
flash heat transfer
in volatility
Distillation L and/or V Heat transfer V or L difference
or shaft work
in volatility
Gas V Liquid L difference
absorbent
Absorption in volatility
Stripping L Vapor stripping V difference
agent
in volatility
Extractive L and/or V Liquid solvent V and L difference
and heat
Distillation transfer
in volatility
Azeotropic L and/or V Liquid V and L difference
entrainer and
Distillation heat transfer
in volatility
Common Industrial Sep.Methods (Cont’d)
Separation Phase of Separation Developed Separation
Method the feed agent or added principle
phase
Liquid-liquid L Liquid Second Difference in
Extraction solvent liquid solubility
Crystalli- L Heat Solid Difference in
zation transfer solubility or
m.p.
Gas V Solid Solid difference in
adsorption adsorbent adsorbabililty
Liquid L Solid Solid difference in
adsorption adsorbent adsorbabililty
Membranes L or V Membrane Membrane difference in
permeability
and/or
solubility
- 4Separation Trains DESIGN AND ANALYSIS II - (c) Daniel R. Lewin 9
Common Industrial Sep.Methods (Cont’d)
Separation Phase of Separation Developed Separation
Method the feed agent or added principle
phase
Supercritical L or V Supercritical Supercritical Difference
extraction solvent fluid in solubility
Leaching S Liquid L Difference
solvent in solubility
Drying S and L Heat V Difference
transfer in volatility
2. Separation factor (Energy or Mass)
The separation factor, SF, defines the degree of
separation achievable between two key components
of the feed.
This factor, for the separation of component 1 from
component 2 between phases A and B, for a single
stage of contacting, is defined as:
𝐶1𝐴 /𝐶2𝐴 C = Composition variable
𝑆𝐹 = 𝐵 𝐵 Phases rich in components 1 and 2.
𝐶1 /𝐶2
Note: SF is selected according to their ease of recovery for recycle and to achieve relatively large values.
2. Separation factor (Energy or Mass)
SF is generally limited by thermodynamic equilibrium, ESA.
For example, in the case of distillation,
Let:
• Mole fractions as the composition variable;
• Phase A be the vapour and phase B be the liquid;
The limiting value of SF is given in terms of vapour-liquid
equilibrium ratios (K-values) as:
y1 / x1 K1 P1 s
SF 1,2 s for ideal L and V
y2 / x2 K2 P
2
2. Separation factor (Energy or Mass)
• For vapor-liquid separation operations (extractive
distillation) that use an MSA
1L P1 s
SF 1,2
2L P2s
• For Liquid-liquid extraction, the SF is referred to as the
relative selectivity, b , where:
1II / 2II
SF b1,2
1I / 2I
Note: Both case is when the MSA is used to create liquid phases which MSA will causes the
formation of a non-ideal liquid solution )
3. Sequencing of OD Columns
Use a sequence of ordinary distillation (OD) columns provided:
• in each column is > 1.05.
• The reboiler duty is not excessive.
• The pressure does not cause the mixture to approach the TC
• Column pressure drop is tolerable.
• The overhead vapor can be at least partially condensed at the column
pressure to provide reflux without excessive refrigeration
requirements.
• The bottoms temperature is not high that chemical decomposition.
• Azeotropes do not prevent the desired separation.
3. Sequencing of OD Columns
Number of Sequences for Ordinary Distillation, Ns is
determined by
[2(P 1)]!
Ns
P ! (P 1)!
# of Product, P # of Separators Ns
2 1 1
3 2 2
4 3 5
5 4 14
6 5 42
7 6 132
8 7 429
3. Sequencing of OD Columns
Example 1 : Sequences for 4-component separation
3. Sequencing of OD Columns
Example 1 : Sequences for 4-component separation
3. Sequencing of OD Columns
Example 2 : Sequences for 4-component separation
4. Pressure & Temperature operating
condition
Separation involves complex system
S02
For a binary mixture, it may be possible to select a A
separation method that can accomplish the
separation task in just one piece of equipment.
However, more commonly, the feed
mixture involves more than two S01
A
components, involving more complex B
separation systems.
V01
Feed
37.8 oC, 1.03 MPa Propane
S03
Propane
1-Butene
n-Butane
trans-2-Butene
? n-Butane B
Mixtures of Butene
cis-2-Butene
n-Pentane
separation systems
n-Pentane
Example 2: Design for Butenes Recovery System
Example 2: Design for Butenes Recovery System
100-tray column C3
& 1-Butene in
distillate
Propane and 1-
Butene recovery
Pentane withdrawn
as bottoms n-C4 and 2-C4=s
cannot be separated
by ordinary
distillation (=1.03),
so 96% furfural is
added as an
2-C4=s withdrawn as extractive agent (
distillate. Furfural is 1.17).
recovered as bottoms n-C4 withdrawn as
and recycled to C-4 distillate.
Example 2: Design for Butenes Recovery System
S04
(Simplified) A
S02
C2
A
B
D S08
S05
E C
S01 C1A
C1B B,D,E
A
B
C S06 C4A
D C4B
C C5
E D
F
Legend: E
A: Propane S03 S09
B: 1-Butene C3
C D
C: n-Butane E
D
D: trans-2-Butene E
E: cis-2-Butene F S07
F: n-Pentane
F
Exercise 1: Determine number of possible
sequence.
Number of possible sequence: 14 14
(5 components)
End
Next Class: Chapter 3b - Selection Methods
