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Ian A. Furzer†
A wastewater stream containing minor amounts of ethyl acetate and ethanol could produce
clean water with a low solvent composition by the use of direct steam injection or by the use of
a distillation column. A problem that arises in this system is the approach to a homogeneous
azeotrope in the distillate as the number of ideal stages is increased. Higher compositions of
ethanol can be produced at low distillate flow rates by limiting the number of ideal stages. The
prediction of the azeotrope in this system requires new UNIFAC vapor-liquid equilibrium
interaction parameters, which have been determined. Simulation of a distillation column at
total reflux then predicts a maximum in the ethanol composition which could be recovered and
recycled in the plant. The value of this recycled ethanol can exceed the steam operating costs
for the wastewater plant. A cost optimization shows that there is a cost-feasible region that
satisfies the composition constraints when the reflux ratio is between 10 and 30, with low D/F
ratios, for an eight-stage column. The procedures outlined in this paper could be expected to be
general and to apply to other ternary systems that exhibit a homogeneous azeotrope.
{ }
control of separation sequences involving homogeneous K1,i K2,iV F1
and heterogeneous azeotropic systems has been com- F1,i ) (RD - V) - 1 x1,i + x2,i + xF,1,i
pleted by Widagdo and Seider.1 Further extensions have L L L
been made by Stichlmair and Fair.2 The review covers i ) 1, 2, ..., nC (1)
distillation lines which show the liquid composition path nC
∑
at total reflux on a triangular diagram. These distilla-
tion lines are often shown as continuous lines to F1,nC+1 ) 1 - x1,i (2)
i)1
demonstrate the feasibility of a separation in the
presence of stable and unstable nodes and saddle points. Stage n
{ } { }
Computation of distillation lines with a finite number
Kn,iV Kn+1,iV
of ideal stages in the column leads to a series of discrete Fn,i ) Lxn-1,i - + 1 xn,i + xn+1,i +
points representing the liquid compositions at total L L
reflux on the stage. Linking of these discrete points by Fn
lines leads to a discontinuous distillation line, with x i ) 1, 2, ..., nC (3)
L F,n,i
gradient changes on each side of a discrete composition
nC
point. It is useful to describe this type of distillation line
as a discrete distillation line or a stagewise distillation Fn,nC+1 ) 1 - ∑ xn,i (4)
line. These lines are normally only used for ternary i)1
systems on a triangular diagram. The extension to a Stage N
{ }
quaternary system becomes visually complex but can
be viewed on a 3D rotating computer image. For four L KN,iV FN
or more components in the system, it is possible to plot FN,i ) xN-1,i - + 1 xN,i + xF,N,i
LN LN LN
the composition profile along the column, but this does
not provide the visual impact of directed discrete i ) 1, 2, ..., nC (5)
distillation lines in a ternary system, pointing toward nC
a ternary azeotrope. The complexities of these distilla-
tion lines when multiple steady states occur have been
FN,nC+1 ) 1 - ∑
i)1
xN,i i ) 1, 2, ..., nC (6)
outlined by Esbjerg.3
Error Condition
x∑ ∑
Discrete Distillation Lines at Total Reflux N nC+1
1
Process simulation studies of multicomponent distil- e Fn,i2 i ) 1, 2, ..., nC (7)
lation columns are based on the solution of the mass, N(nC + 1) n)1 i)1
The K values and the temperature and composition Table 1. New UNIFAC VLE Interaction Parameters
gradients use the UNIFAC method as given by main groupsa
1 5 7 11
γn,iPSi
Kn,i ) i ) 1, 2, ..., nC n ) 1, 2, ..., N (8) 1 0.0 2491.52 475.67 20.401
Pn 5 330.61 0.0 92.486 75.488
{ }
7 255.97 93.919 0.0 72.000
∂Kn,i 1 ∂PSi ∂γn,i 11 688.60 255.26 395.45 0.0
) γn,i + PSi (9) a Main groups: 1, CH2; 5, OH; 7, H2O; 11, CCOO.
∂T P ∂T ∂T
The UNIFAC method is based on geneous ternary azeotrope in the ethyl acetate-etha-
nol-water system cannot be predicted by the use of the
C R
ln γn,i ) ln γn,i + ln γn,i (10) UNIFAC VLE interaction parameters. When the total
reflux distillation program is run with the UNIFAC
R
ln γn,i ) ∑νiR{ln Γk - ln Γik} (11) VLE parameters, discrete distillation lines are gener-
ated which do not terminate at the ternary homoge-
Equation 11 contains a term that includes the interac- neous azeotrope. The generation of additional discrete
tion parameters amn. distillation lines using UNIFAC VLE interaction pa-
rameters could be expected to generate low-quality
Ψmn ) exp{-amn/T} (12) process simulation results, which would be unsatisfac-
tory for chemical engineering design.
Operation of these process simulation packages at Furzer6 has collected a wide range of experimental
high reflux ratios provides an approach to the stage VLE data in the system ethyl acetate-ethanol-water
compositions at total reflux. The system equations at and determined a new set of UNIFAC VLE interaction
total reflux result in modifications to the normal MESH parameters for the main groups 1, 5, 7, and 11 by a data
equations. For example, there are no feed, distillate, or regression analysis. Table 1 shows this new set of
bottoms streams when columns are operated at total interaction parameters.
reflux. The initial charge to the column provides an A single-stage, multicomponent flash program con-
initial mass balance for each component which must be verges accurately on the ternary homogeneous azeotrope
conserved when the column reaches steady-state condi- with these new UNIFAC VLE interaction parameters.
tions at total reflux. The deviation functions to satisfy A total reflux distillation program with a large number
this condition are of ideal stages generates a set of discrete distillation
N
lines which point toward or approach the ternary
∑ mnxn,i - FxF,i
homogeneous azeotrope. The root-mean-square (RMS)
FN,i ) i ) 1, 2, ..., nC (13) error in the vapor compositions is satisfactory for the
n)1
collection of ternary experimental VLE data, and this
Cairns and Furzer5 have modified the Naphtali- new set of UNIFAC VLE interaction parameters could
Sandholm approach by introducing the initial conserved be used for chemical engineering design. Experimental
charge, given by eq 13, and the total reflux deviation VLE data are not available when one of the components
functions, given as follows: in the ternary mixture is very dilute, and UNIFAC with
the new discrete distillation line VLE interaction pa-
Fn,i ) yn+1,i - xn,i n ) 1, 2, ..., N; i ) 1, 2, ..., nC rameters is needed to predict VLE data in these special
dilute regions.
(14)
Figure 1 shows discrete distillation lines generated
Solution of this modified set of MESH equations pro- by the total reflux distillation program using the new
vides the simulated or predicted liquid compositions on UNIFAC VLE interaction parameters, for eight ideal
ideal stages in the column under total reflux conditions. stages in the column, and different initial charges to
Input to this total distillation program requires the the column. These lines are limited in their approach
input of the distribution of the holdup in the distillation to the ternary homogeneous azeotrope, with only eight
system. ideal stages. A deeper approach requires an increase in
The system ethyl acetate-ethanol-water forms a ideal stages and would crowd the figure. Discrete
minimum boiling point homogeneous azeotrope, with distillation lines only show the liquid compositions on
a composition of x(EtAc) ) 0.595 (mole fraction), the stages. The enriched vapor from the top stage is
x(EtOH) ) 0.115, and x(W) ) 0.290 at a total pressure totally condensed and refluxed to the column. This
of P ) 101.3 kPa. The use of the UNIFAC group additional enrichment is not shown on these discrete
contribution thermodynamic model to predict the vapor- distillation lines. A characteristic of the lines is the very
liquid equilibrium (VLE) data in this system uses VLE large composition changes from stage to stage in certain
main groups 1, 5, 7, and 11, corresponding to the CH2, regions of the VLE composition space. Because of these
OH, H2O, and CCOO groups. The deviation functions large composition changes, discrete distillation lines can
for an azeotrope are given by intersect. The set of predicted discrete distillation lines
is a more complex package than simple, separated,
F1,i ) y1,i - x1,i i ) 1, 2, ..., nC (15) smooth distillation lines shown in sketches. The discrete
distillation lines also show a maximum composition of
The use of a single-stage, multicomponent flash ethanol at intermediate stages in the column. Several
program using the UNIFAC VLE interaction param- of the lines shown in Figure 1 show ethanol composi-
eters fails to find a solution to eq 15. An important tions in excess of 0.600 (mole fraction) at these maxima.
consequence of this negative result is that the homo- The actual positions of the maxima are highly depend-
Ind. Eng. Chem. Res., Vol. 39, No. 6, 2000 1541
Figure 1. Discrete distillation lines at total reflux: ethyl acetate- Figure 2. Dilute composition region at total reflux: ethyl
ethanol-water. acetate-ethanol-water.
Figure 5. Discrete distillation lines at a finite reflux ratio. Feed Figure 7. Discrete distillation lines at a finite reflux ratio: effect
composition change: xF(EtAc) ) 0.0080; xF(EtOH) ) 0.0400. of reflux ratio.
Figure 6. Discrete distillation lines at a finite reflux ratio. Feed Azeotropic Column Cost Optimization
composition change: xF(EtAc) ) 0.0020; xF(EtOH) ) 0.0400.
A wastewater distillation column may contain a
xF(EtAc) ) 0.0020 (29) steam-heated reboiler or use direct-injected steam. For
an existing wastewater column with a fixed capital cost,
xF(EtOH) ) 0.0400 (30) it is possible to optimize the steam costs by recovering
valuable solvents. The operating cost of steam will be
D/F ) 0.0420 (31) the major operating cost in the wastewater plant. It can
be shown that the steam-to-feed ratio (S/F) is given by
The results of the three simulation runs on different
feed compositions are given in Table 2. S/F ) (R + 1)(D/F) (32)
Figure 7 is for solvent feed compositions given by eqs
29 and 30 with the D/F ratio set to 0.0600 and the reflux Increased steam operating costs (COP) will be associ-
ratio varied. At high reflux ratios from 10 to 30 the ated with increases in both R and the D/F ratio. If the
separation is satisfactory. When the reflux ratio is set cost of steam (CS) is known at the plant, then
at 1, 2, or 3, considerable deviations from the overall
mass balance line occur. A reflux ratio of 5 is required COP/F ) CS(S/F) (33)
before there is a reasonable approach to the overall mass
balance line and a satisfactory separation. The visual COP/F ) CS(R + 1)(D/F) (34)
1544 Ind. Eng. Chem. Res., Vol. 39, No. 6, 2000
Figure 8. Bottoms composition of ethanol: effect of reflux ratio. Figure 9. Composition constraint diagram: ethyl acetate-
ethanol-water.
It is useful to consider the value of the ethanol content
in the recovered distillate. A recycled distillate stream C ) CEtOH(D/F)xD(EtOH) - CS(R + 1)(D/F) (40)
can reduce the purchase costs of ethanol (CEtOH) in an
ethyl acetate reactor or reactive distillation column. The subject to the constraints
equivalent revenue (CREV) is obtained from the replace-
ment of purchase costs of ethanol by xD(EtOH) g 0.600 mole fraction (41)
A cost objective function (C) can be established by Figure 9 shows the constraints on the distillate and
bottoms for ethanol. To satisfy the constraints given by
CREV COP eqs 41 and 42, it is necessary to operate in the upper
C) - (36) left rectangle with two sides bounded by the constraints.
F F
A process simulation study with solvent feed composi-
When the cost function is positive, the wastewater tions given by eqs 29 and 30 provides the distillate and
plant is generating a positive cash flow condition. When bottoms compositions for ethanol at various reflux ratios
the cost function is zero, there is a break-even condition, and D/F ratios. Figure 9 shows the linked discrete liquid
which is of particular importance in considering the composition points at reflux ratios of 20 and 30 to cover
design of wastewater plants. Equations 34, 35, and 36 the cost break-even conditions when the reflux ratio is
at this break-even point give between 23 and 27. Both of these lines pass through
the feasible solution region at the cost break-even
R ) (CEtOH/CS)xD(EtOH) - 1 (37) condition. The optimal or maximum profit on the cost
function given by eq 40 is at the intersection of the
if constraints, where the reflux ratio is 9. If the waste-
water plant was operated with a reflux ratio of 9, it
CEtOH/CS ) 40 (38) would operate at a maximum profit.
Figure 9 also shows lines at various D/F ratios. At
and the optimal solution where the reflux ratio is 9, the D/F
ratio is 0.067. Both of these results are important for
xD(EtOH) ) 0.600 (39) the profitable operation of the wastewater column. It
is also possible to relax the optimal solution and accept
then R ) 23. profitable solutions that lie between the break-even
If xD(EtOH) was increased to 0.700 mole fraction, the reflux of 23 and the two constraints. If the ethanol
break-even value of R would be 27. A break-even cost composition of the bottoms was held constant at 10 ppm,
point is reached in the wastewater plant when the reflux then it would be possible to withdraw distillate with an
ratio is 23 and the distillate composition contains 0.600 ethanol composition of 0.700 mole fraction at a reflux
mole fraction of ethanol. If the wastewater column is ratio of 27 and a D/F ratio of 0.057 at the break-even
operated at a reflux ratio of less than 23, it would point. This provides some operating flexibility in recy-
generate a cost profit on ethanol recovered and recycled. cling the distillate in regards to ethanol composition,
However, it would need to satisfy the constraints on while maintaining a break-even or profitable economic
ethanol composition in the distillate and ethanol com- condition. If the ethanol composition of the distillate was
position in the bottoms. The problem can be expressed held constant at 0.600 mole fraction, then at the break-
as an objective function even point the ethanol composition of the bottoms would
Ind. Eng. Chem. Res., Vol. 39, No. 6, 2000 1545
be 1 ppm at a reflux ratio of 23 and a D/F ratio of 0.067. Ps ) saturated vapor pressure, Pa
Figure 9 shows that the operating window between the R ) reflux ratio
break-even condition and a profitable condition, while S ) steam flow rate, kgmol s-1
satisfying the constraints, is reasonably large and T ) temperature, K
permits the operator to modify processing conditions V ) vapor flow rate, kgmol s-1
when they are required. x ) liquid composition
xF,i ) liquid composition, feed, component i
y ) vapor composition
Conclusions
Subscripts
The recovery of solvents ethyl acetate and ethanol
from a wastewater stream can be cost-effective in the i ) component identification
operation of a wastewater plant which has a low n ) stage number
composition specification of solvent in the recovered nC ) number of components
water. A homogeneous ternary azeotrope exists in the Superscripts
system ethyl acetate-ethanol-water, and the quality
C ) combinatorial part
of a process simulation study requires a good prediction R ) residual part
of this azeotrope. New parameters for the UNIFAC
model are given in this paper which provide this good Greek Letters
prediction. A total reflux simulation of a distillation γ ) activity coefficient
column with these new parameters generates discrete ) error value
liquid composition points or discrete distillation lines
that are directed toward the azeotrope. High composi- Literature Cited
tions of ethanol are predicted at intermediate values of
the number of ideal stages in the column. An increase (1) Widagdo, S.; Seider, W. D. Azeotropic Distillation. AIChE
J. 1996, 42, 96-130.
in the number of stages leads to a reduced ethanol (2) Stichlmair, J.; Fair, J. R. Distillation: Principles and
composition, approaching the azeotropic value. Experi- Practices; John Wiley and Sons: New York, 1998.
ence in simulation at a finite reflux is necessary by (3) Esbjerg, K.; Anderson, T. R.; Muller, D.; Marquardt, W.;
adjusting the D/F ratio to satisfy both solvent recovery Jorgensen, S. B. Multiple Steady States in Heterogeneous Azeo-
and wastewater cleanup quality. A process cost estima- tropic Distillation. Ind. Eng. Chem. Res. 1998, 37, 4434-4452.
tion, subject to composition constraints, leads to a (4) Furzer, I. A. Distillation for University Students; Depart-
ment of Chemical Engineering, University of Sydney: Sydney,
feasible cost region for this wastewater cleanup problem. Australia, 1986; pp 201-205.
Values of the reflux ratio between 10 and 30 at low D/F (5) Cairns, B. P.; Furzer, I. A. Multicomponent Three-Phase
ratios can provide cost-effective cleanup conditions in a Azeotropic Distillation. 1. Extensive Experimental Data and
column with eight ideal stages. This type of optimization Simulation Results. Ind. Eng. Chem. Res. 1990, 29, 1349-1363.
provides a good insight into a detailed optimization (6) Furzer, I. A. Critical Process Modelling in Separation
study of a wastewater stream containing other solvents, Systems. Chemeca98, 26th Australian Chemical Engineering
Conference, Port Douglas, North Queensland, September 28-30,
that could generate a homogeneous azeotrope. 1998.
(7) Furzer, I. A. Experimental Heterogeneous Distillation in the
Nomenclature System: Ethanol-Water-Ethyl Acetate. AIChE National Spring
Meeting, Houston, TX, March 19-23, 1995.
B ) bottoms flow rate, kgmol s-1 (8) Furzer, I. A. Distillation in Ternary Azeotropic Systems.
C ) cost objective function Chemeca98, 26th Australian Chemical Engineering Conference,
D ) distillate flow rate, kgmol s-1 Port Douglas, North Queensland, Australia, Sept 28-30, 1998.
F ) feed flow rate, kgmol s-1 (9) Furzer, I. A. Froth Heights on Dualflow Trays with a
FN,i ) deviation function Ternary Azeotropic System: Ethyl Acetate-Ethanol-Water. Ind.
K ) K value Eng. Chem. Res. 1999, 39, 1430-1436.
L ) liquid flow rate, kgmol s-1
Received for review February 22, 1999
m ) mass of liquid holdup, kgmol Accepted February 9, 2000
N ) total number of stages
P ) total pressure, Pa IE990133X