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Printed 1x1Great Britain. All rights reserved CopyrIght C 1989 Persamon Press plc
(Receioed 27 October 1987; final revision received 6 April 1989; received forpublication 28 April 1989)
Abstract-The mathematical model of a semi-batch supercritical fluid extraction process has been derived;
its implementation is divided into two distinct stages. Firstly, the differential equations that represent the
dynamic behavior of the process are derived. Secondly, a thermodynamic model suitable for representation
of phase behavior is selected and the algebraic equations and the parameters which describe the process
are identified.
The proposed algorithm is used to simulate the fractionation of ethanol from a water mixture using
carbon dioxide, and the supercritical extraction of citral from lemon oil with carbon dioxide. The program
is applicable to the simulation of extraction from liquids and, with some modifications, from solids.
1175
1176
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1 2
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Q,
G. CESARI er cd
P, T
p,
,c 98
F, H,
------------J
analyzed by introducing another set of NC variables substitution was made on the basis of a test consider-
which represent the integral with time of the inputs ing the variation to which the values are subject in
to the separator itself, qint,: time.
The compressibility factors and the instantaneous
d/d?@;) + d/dt(q,) = F, - Gq,/Zq, (i = 1, NC),
separation factors were calculated at each integration
(1) step and compared to the previous value: if the
variation of at least one of them was bigger than 1%
d/dr(qint,) = Gq;/Zq,(i = 1,. . NC), (2) they were updated and the stability of the phases was
d/dt (h,EP, + h, Zy,) = II,CF, - h, G + Q (3) checked in order to maintain the proper phase distri-
bution, particularly in the critical region. The stability
q,/Cq, = kjpi/Epj(i = 1, . . NC), (4) test included in the algorithm was that developed by
V,,, = (RTIP)(ZqEQi + Zq%j), (5) Michelsen (1982).
The model used for describing the thermodynamic
G = IP~VI(P~Z,)‘~2111(P2 - J’~v)/pmll behavior of the mixture must be considered here as
x [(L/D)1 - 2 ln(P,,/P]}t’2. (6) an example of rigorous equation of state suitable for
thermodynamically describing the system. Any model
Equation (6) is derived from an energy balance
can be used; it must be able to calculate fugacity
around the pressure reduction valve assuming turbu-
coefficients and their derivatives for all the com-
lent flow (resistance number 1 constant) and com-
ponents in all the phases present at equilibrium in the
pressibility factor constant in the interval of time
mixture (Bertucco et al., 1986).
considered.
An attempt was made to find operating conditions
The enthalpies that appear in the energy balance
that guaranteed, throughout the simulation, separa-
equation (3) are functions of pressure, temperature
tion into a high-density phase and a low-density one.
and composition as indicated in the following equa-
Finally, control by a valve of the proportional type
tions for the high-density and low-density phases,
has been used in the fluid-dynamic relationship, that
respectively:
is:
h, = h,(p, T, P), (7)
P = B0 + k,(P - PO)> (11)
h, = h, (9, T, P). (8) where: PO is the set-point pressure, POis the coefficient
The thermal power Q exchanged externally of opening calculated in static conditions.
can be expressed as a function of temperature, as The thermodynamic model used for the calculation
follows: of the fugacity coefficients, and consequently the
instantaneous separation factors, is the key point of
Q = k(G - T), (9) the performance of the simulation, since in dynamic
where r, is the set-point temperature. processes the error is cumulative.
The equilibrium relationships (4), the volumetric The literature reports many equations of state
congruency relationship (5) and the fluid-dynamic capable of describing multicomponent mixtures of
relationship (6) contain the equilibrium constants ki different kinds. Among the others we have selected
and the compressibility coefficients Z, and Z, of the and included in the program the following models:
high- and low-density phases. Since the use of the Soave-Redlich-Kwong (SRK) (Soave, 1972),
term “equilibrium constant” may be confusing in Percus-Yevick-Redlich-Kwong (PYRK) (Mathias et
time domain, from now on the term “instantaneous al., 1986), and Skjold Joergensen’s GCEOS (Skjold
separation factors” will be used. In effect: Joergensen, 1984). The models have been chosen in
order to include in the program well-known (indus-
k, = k,(P, 9. T PI.
trially applied) as well as more complicated but more
2, = Z,(P, T, P). accurate equations. In particular, GCEOS has been
selected for its capability of describing polar systems
z, = z, (cl, r, P), (10)
and ill-defined molecules (key components in natural
that is to say, even these coefficients are functions of products).
the variables of the system of equations and, conse-
quently, are time dependent. However, they have NUMERICAL SOLUTION
been considered constant over intervals of time: in
The method of integration
fact, since it is not possible to obtain a simple
analytical expression for them to be included into the The system to be integrated is a system of differen-
system of equations to be integrated (at least not tial equations coupled with a system of algebraic
without artificially simplifying the thermodynamic equations which present the characteristics of being
models), they have been recalculated periodically stiff. It was integrated using the LSODI routine from
using the equation of state and the values obtained the ODEPACK package developed at the Lawrence
have been substituted, as appropriate, in the System Livermore Laboratory (Hindmarsh, 1981). This pro-
of equations during the integration course. The gram provides for the utilization of both Gear’s
117x G. CESARl 6?!Cd.
method, which is based on the so-called BDF formu- obtain even this partial result 600 s of CPU time wcrc
lae (backward differentiation formula) and of Adams’ needed.
implicit method. Gear’s method is one of the most The program has also been implemented on an
efficient for the intcgratlon of stiff systems and has IBM AT (Intel 80286’80287) system with a Microsoft
thus been selected. In order to improve efficiency, the Fortran 4.01 compiler. The total computer time for
Jacobian of the system was calculated analytically. the above example was of 450 s using Gear’s method
The program resolves systems written in the tbl- of integration. In this case graphic output of the
lowing form: dependent variable vs time is also provided. The
figures reported in the paper are directly plotted by
A(t. v)v = G(r, v) (12)
the program.
where A IS a squared matrix, v and G are vectors and
I the independent variable. If lr, is not singular the
RESLILTS
system of equations is purely differential; if it is
singular, the system is algebraic--differential. In that The implementation of the algorithm considered
case it IS necessary to calculate, in addition to the has allowed the study of the dynamics of the process.
initial conditions (i.e. the values of the variables at that is to say, the cvolutlon in time of the character-
the initial instant). the values of the derivatives at the istic properties of the process. i.e. the concentration
initial instant. of the components in the phases. pressure. tempera-
The initml conditions. that is the compositions of ture and flow. ‘The program in the present version
the phases in the extractor at time LeTo, were calcu- treats fluid phases, provided the equation of state is
lated with the equation of state considering the applicable to that kind of mixture. Modifications
composltion of the loaded material and the pressure would be necessary to handle pure solids since the
reduction valve completely closed. The initial deriva- solid species normally exist in pure (single-compo-
tives were calculated using Dini’s Thsorem. nent) phases and therefore the K-factor definition
[equation (4)1 does not apply. Another crucial prob-
lem limiting the applicability in the case of cxtractinn
The simulation program known as CISO (com- from solici materials is the availability of equilibrium
puter simulation of implicit systems). which implc- data, and consequently, of the model parameters.
ments the mathematical model of the plant, has a Two examples have been considered in order- to
modular structure. It consists of three parts: the main demonstrate the capabilities of the program.
program defines the system of equa!ions to bc intc-
grated: the LSODI routine carries out the integration
of the system; the thermodynamic routines calculate
the equilibrium properties and periodically updates The first example has been selected for the com-
their values for use in the system of equations. ‘This plete availability of experimental equilibrium da&,
modular structure provides a flexible instrument model parameters and experimental extraction data.
which can be tailored to various situations. This example should be interpreted as a demonstra-
One point which has been gone into in some detail tion of the program rather than a real feasibility study
is that relating to the computer time necessary to of the separation. The fugaclty coetticients defining
carry out a simulation cxtcnded over a sufficiently the K-values are calculated by means of the <KWX
long interval of time (of simulation). To establish a model, which takes into account the polarity of the
direct comparison, simulation has been performed mixture.
using two different methods of integration, one suited Comparison has been made with cxpcrimental
to stifi systems and one to nonstiff systems: that is to results obtained from an actual plant. The simulation
say. the LSODI integration routine has been utilized conditions have then been chosen to be as near as
selecting first Gear’s method of Integration and then possible to the operating ones. The feed is a mixture
Adams’. The results are significant; the computer of water and ethanol (rich in water) from which the
times requjl-cd by Adams’ method are greater than alcoholic component should be extracted, utilizing
those required by Gear’s, which justifies the u5e of the carbon dioxide as a supercrltical solvent. The charac-
selected method that has, indeed, resulted to be the teristics data of the plant are shown in Table 1.
only one efficient for problems of this kind. The first result obtained was the determination of
The diff’crence in performance between the two the parameters necessary for the regulation of the
methods can be illustrated by the following result: valve in the efflux pipe from the extractor. the values
attempts were made to simulate operation of the of enthalpy of the feed and of thermal power to be
plant for 900 s on a CDC Cyber 730 computer; with exchanged externally m order to keep the tempera-
Gear’s method the integration was achieved in 60.461 ture constant. These values were determined using the
CPU s: with Adams’ method, instead, integration of tuning tnethodulogq proposed by Ziegler and
the system could not be achieved over the required Nichols.
interval of time and. in fact, It was not possible to The proportional control strategy for main-
extend the integration beyond a period of 160 s. To taining the pressure set-point was found to he. in
Program for a semi-batch fluid extraction process 1179
Timz (set)
concordance with the actual experiments, very deli- Fig. 5. Number of moles of CO, and ethanol in the
cate, given the large difference in the pressures up- high-density phase (HD) and number of moles of H,O and
ethanol in the low-density phase (LD) vs time. Big circles are
stream and downstream of the valve, which tend to experimental data.
push the system to the limit of instability, thus
provoking rapid oscillation around the values of
regime (see Fig. 4). Ziegler and Nichols’ tuning was
used for the pressure controller; the controller gain
used was K, = 0.2; no saturation of the pressure often at the beginning of the simulation. The stability
control valve was encountered during the simulation test is performed when the control action is substan-
(Cesari, 1986). tial (i.e. compressibility factors or K-factors relative
The temperature was found to be notably depen- variation bigger than 1%) in order to maintain the
dent on the enthalpy of the feed and possessed proper phase distribution. If a phase is eliminated by
considerable inertia. This confirms the experimental the controllers the simulation is carried on with a
results; in general, it is necessary to wait a long time pseudo-phase. The pseudo-phase is generated by the
to reach the set-point temperature before beginning density calculation routine of the thermodynamic
the extraction process. It is also necessary to use a model.
thermostatic bath held at a temperature about 20” Figure 5 shows the variations in the number of
higher than that of the set-point and to pay particular moles in the high-density (HD) and in the low-density
attention to the thermal characteristics of the feed phase (LD). The high-density phase remains preva-
flow. The controller gain used was K, = 50. lently constituted by H,O; however, whilst the num-
It has been observed that the greatest variation of ber of moles of CO, in the high-density phase is
the K-factors with time occurs at the beginning of the practically constant with time, the number of moles
extraction process when variations in the concen- of C, H, OH diminishes drastically as extraction pro-
trations of the components in the two phases inside ceeds. The low-density phase consists prevalently of
the extractor are at their greatest. Whilst the K-fac- CO,; moreover, whilst the number of moles of H,O
tors vary notably with time, the compressibility co- present in the low-density phase remains constant,
efficients remain practically constant. Consequently the number of moles of C? H,OH diminishes notably.
the thermodynamic/stability routine is called rather The agreement between the calculated results and
the experimental data obtained in the pilot plan
Pa (Bartolomeo et al., 1986) is satisfactory as it can be
1; clearly seen in the figures where the experimental
extraction data are shown with a circle. The experi-
mental data were obtained by performing extractions
with the same operative conditions at different total
extraction times. The analyses were made by gas
chromatography. Experimental data for the low-
density phase were not available because an on-line
analyzing device could not be placed at the outlet of
the extractor. The agreement is not perfect because of
the experimental difficulty in control and measure-
ment of the flowrate of CO1 in the input to the
extractor and because mass transfer phenomena are
not considered.
169. Figure 6 reports the results of the simulation in
terms of mol fractions (option in the program) so as
Fig. 4. The pressure as function of time in the extraction to provide more suitable information for scaling up
stage of the process (Example 1). the process.
1180 G. CESARI et al
Mole fractions are calculated by the PYRK model since this model
is suitable for describing the system (Mathias ef al.,
1986). The parameters of the model have been deter-
mined from equilibrium data (Kalra et al.. 1987). By
considering the experimental data one can already
detect a relatively low selectiGty of citral with respect
to limonene.
It is evident from Fig. 7 that a single-stage extrac-
tion is not suitable due to the necessity of recovering
the product of interest as raffinate. In fact. 8576 ofthe
loaded mixture should be extracted in order to obtain
a 10% citral concentration. Unfortunately, no exper-
imental data are available for the comparison of the
Fig. 6 Mel fractions of CO, and ethanol in the high-density dynamic simulation.
phase (HD) and mol fractions of I-1,0 and ethanol in the
low-density phase (1-D) YStime. Big circles are experimental
data CONCLUSIONS
REFERENCES
NOMENCLATURE
Bartolomeo G., A. Bertucco, G. 3. Guarise and S. A.
A, = Cross-sectional area of the outlet from the extrac- Rienzi, Estrazione con fluidi in condizioni supercritiche:
tor. impianto sperimentale. &a. Comb. 15, 185 (1986).
E = Fraction of c&al extracted with respect to its Bertucco A., M. Fermeglia and I. Kikic, Modified Carna-
initial amount (Fig 7). ban-Starling-Van der Waals equations for supercritical
F, = Extractor feed flow in moles of component i fluid extraction. Chem. Engng J. 32, 21 (1986).
G = Molar Sow of the low-density phase at outlet &sari G. ~odelli~~one, simulazione e controllo di
h, = Enthalpy per molar unit of feed flow impianti chimici: appficazione all’ estrazione supercritica
h, = Enthalpy per molar unit of dense phase present Thesis, University of Trieste (1986).
in extractor Feng A., C. D. Holland and S. E. Gallun, Development and
h, = Enthalpy per molar unit of low-density phase comparison of a generalized semi-implicit BungeeKutta
present in the extractor method with Gear’s method for systems of coupled
K, = Instantaneous separation factor of component i differential and algebraic equations. Comput. them. Engng
k, = Controiler gain 8, 51 (1984).
L/L) = Equivalent length of tube Finlahsen G., Nvniinear Analysis in Cbemicut Engineering.
NC = Number of components present in the extractor McGraw-Hill, New York (1980).
Q = Amount of high-density phase in the extractor at Gallun S. E. and C. D. Holland, Gear’s procedure for the
any time/initial amount of feed (Fig 7). simultaneous solution of differential and algebraic equa-
P = Pressure inside the extractor tions with application to unsteady state distillation prob-
P,, = Pressure downstream of the valve lems. Cornput. ehrm. Engng. 6, 244 (1982).
p, = Number of moles of component i in dense phase Hindmarsh A. C., ODEPACK, Lawrence Livermore Na-
present in extractor tional Laboratory (1981).
PO= .%-point pressure Holland C. D. and A. I. Liapis, Computer Methods fir
p” = Molecular weight of supercritical solvent Sotuing Dynamic Sepwution Problems. McGraw-Hill,
Q = Thermal power exchanged between extractor and New York (1983).
its ambient Kalra H., S. Y. K. Chung and C. J. Chen, Phase equilibrium
.q, = Number of moles of component i in the extractor data for supercritical extraction of lemon flavors and
(low density phase) palm oils with carbon dioxide. Fluid Phase Eq~~ljbriu 36,
qint, = Integral of component i at outlet from extractor. 263 (1987).
R = Universal gas constant Mathias P. M., Copeman T. W. and Prausnitz J. M., Phase
T = Tem~rature equilibria for supercritical extraction of lemon flavors and
r, = Set-pomt temperature palm oil with carbon dioxide. Florid Phase Equilibria 29,
V,,, = Volume of extractor 545 (1986).
x = Weight fraction of citral in the high-density phase Michelsen M. The isothermal Aash problem. Part 2: phase
(Fig. 7) split calculation. Fluid Phase ~q~i~ib~iu 8, 21 (1982).
~1= Weight fraction of citral in the low-density phase Skjold Joergensen S., Gas solubility calculations. 11. Appli-
(Fig. 7) cation of a new group-contribution equation of state.
2, = Coeflicient of compressibility of high-density Fluid Phase Eq~~~ibT~a16, 317 (1984).
phase Soave G., Equiiibrium constants from a modified
Zs = Coefficient of compressibility of low-density Redtich-Kwon8 equation of state. C&m. Engng Sci. 37,
phase 463 (1972).