DEPARTMENT OF CHEMICAL ENGINEERING

BANSILAL RAMNATH AGARWAL CHARITABLE TRUST'S

VISHWAKARMA INSTITUTE OF TECHNOLOGY PUNE-411 037

(An Autonomous Institute Affiliated to University of Pune.)

CERTIFICATE
This is to certify that the course project report titled Challenges in Multi-Component Distillation
has been completed by Viraj khandagale, Yash Wagh, Y D Satyamedha, Bharat Jagtap ,Kanak
Gupta, Aishwarya Karangale in the academic year 2022 – 2023, in partial fulfillment of T.Y. B.
Tech. in Chemical Engineering.

PROF. Tanushree Bhattacharjee PROF. Dr. M. P. DEOSARKAR

(Guide) (HOD)

Vishwakarma Institute of Technology, Vishwakarma Institute of Technology,

Pune Pune

Place: Pune
Date:
 BANSILAL RAMNATH AGARWAL CHARITABLE TRUST’S

VISHWAKARMA INSTITUTE OF TECHNOLOGY PUNE-411037

(An Autonomous Institute Affiliated to University of Pune)

SEMINAR REPORT ON (SEPARATION TECHNIQUES )

ON

TOPIC: - Challenges in Multi-Component Distillation

SUBMITTED BY:

28. Viraj Khandagale

29. Yash wagh
31. YD Satyamedha
46. Bharat Jagtap
48. Kanak Gupta
49. Aishwarya karangale

UNDER THE GUIDANCE OF:

Prof. Tanushree Bhattacharjee

 Challenges in Multi-Component Distillation
Introduction

Multicomponent distillation involves the separation of mixtures consisting of three or more

components, each with different boiling points, compositions, and thermodynamic properties. This
process is commonly used in industries such as petrochemicals, pharmaceuticals, and specialty
chemicals, where the separation of complex mixtures is crucial for product quality and process
optimization. The seminar shed light on the fundamental challenges associated with
multicomponent distillation, including azeotropes, thermal degradation, entrainment, and energy
efficiency. Azeotropes, in particular, present significant hurdles due to their tendency to form
constant boiling mixtures, making separation difficult. Thermal degradation of heat-sensitive
components during distillation can lead to reduced product quality and yield. Entrainment, or the
carryover of liquid droplets with the vapor phase, can further complicate separation processes.

Moreover, the seminar explored advanced techniques, such as extractive distillation, pressure-
swing distillation, and hybrid processes, as potential solutions to overcome these challenges. The
integration of theoretical insights, experimental findings, and case studies provided attendees with
valuable knowledge and strategies to tackle the complexities of multicomponent distillation.
Types of Multicomponent Distillation : -

I. Conventional distillation: This method is used for separating mixtures of components that
have significantly different boiling points. The mixture is heated in a distillation column,
and the components with the lowest boiling points vaporize first and are condensed and
collected. The process is repeated for each subsequent component in the mixture.
II. Extractive distillation: This method involves adding a third component, known as the
entrainer, to the mixture to change the relative volatility of the components, making them
easier to separate by distillation. The entrainer can be a solvent or a chemical that forms an
azeotrope with one of the components in the mixture.
III. Azeotropic distillation: This method is used to separate azeotropic mixtures, which are
mixtures of two or more components that boil at a constant temperature and cannot be
separated by conventional distillation. A third component, known as the entrainer or
azeotrope breaker, is added to the mixture to break the azeotrope and allow for separation
by distillation.
IV. Reactive distillation: This method involves using a chemical reaction to change the relative
volatility of the components in the mixture, making them easier to separate by distillation.
The chemical reaction occurs in the distillation column, and the products are continuously
removed as vapor.
V. Pressure-swing distillation: This method involves varying the pressure in the distillation
column to change the boiling point of the components in the mixture. The pressure is
changed in a cyclical manner to allow for separation of the components.

VI. Membrane distillation: This method involves using a membrane to separate the
components in the mixture based on their vapor pressures. The mixture is heated on one
side of the membrane, and the vapor passes through the membrane to condense on the other
side.
Working of multicomponent distillation

In the case of a multicomponent distillation, the distillation column will have multiple
trays or plates where the separation of each component will occur. The basic working principle of
a distillation column is that the mixture to be separated is introduced at the bottom of the column,
and it rises up through the column while being heated. As the mixture rises, the temperature
decreases gradually, and different components in the mixture start to condense and re-evaporate.
The distillation column consists of three main sections: the reboiler, the distillation column, and
the condenser. The reboiler is located at the bottom of the column and serves to heat the mixture,
causing it to vaporize. The heat source can be steam or a heating coil submerged in the liquid
mixture.
The distillation column is a tall vertical vessel consisting of a series of trays or plates,
which are separated by a small distance, and each plate is designed to allow vapor and liquid to
pass through. The trays allow for multiple separation stages, as each tray facilitates the exchange
of mass transfer between the liquid and vapor phases. The number of trays required in a distillation
column is based on the number of components to be separated and the desired degree of separation.
The condenser is located at the top of the column and serves to cool the vapor back into a liquid.
The cooled liquid is then collected and separated into its individual components.
In a multicomponent distillation, the process is more complex as the column must
separate several components simultaneously. The separation is based on the relative volatility of
each component, which is the ratio of the vapor pressure of each component to the total vapor
pressure of the mixture. Each component will have its own boiling point and vapor pressure, which
affects its behavior during the distillation process. The components with lower boiling points and
higher vapor pressures will condense and evaporate more quickly, while those with higher boiling
points and lower vapor pressures will take longer to condense and evaporate. To achieve
multicomponent distillation, the column is designed with multiple trays that create a series of
stages where the vapor and liquid mixtures can interact. As the mixture rises up through the
column, each stage allows for a partial separation of the components, with the vapor becoming
richer in the more volatile components and the liquid becoming richer in the less volatile
components. As the mixture reaches the top of the column, the vapor is condensed and collected
and then the fractions are analyzed to determine their composition and purity.
Fig :schematic representation of distillation column
The working of multicomponent distillation, broken down into four stages: feed preparation,
vaporization, condensation, and product separation.

1. Feed Preparation:
The feed to a multicomponent distillation column typically consists of a mixture of several
components with different boiling points. Before entering the distillation column, the feed must be
properly prepared to ensure that it meets the specifications required for successful separation. The
feed may need to be pre-heated to the appropriate temperature to ensure complete vaporization,
and any impurities or contaminants present in the feed must be removed through pre-treatment
processes such as filtration or sedimentation.

2. Vaporization:
Once the feed is prepared, it is introduced into the distillation column at the bottom and heated in
a reboiler. As the mixture is heated, the most volatile component will vaporize first and rise up the
column. The vapor moves up through the column and comes into contact with the cooler liquid on
each tray or plate. Each tray facilitates the exchange of mass transfer between the vapor and liquid
phases, allowing the components with higher boiling points to condense and re-evaporate more
slowly, while those with lower boiling points condense and re-evaporate more quickly.

3. Condensation:
As the vapor continues to rise up through the column and interact with the liquid on each tray, the
composition of the vapor and liquid phases changes gradually. At the top of the column, the vapor
is cooled and condensed back into a liquid, which is then collected in the condenser. The condenser
can be a shell and tube or plate heat exchanger, which uses a coolant such as water or air to remove
the heat of condensation and maintain a temperature gradient across the column.

4. Product Separation:
The collected liquid is then separated into individual products based on their relative volatility.
The products with lower boiling points and higher vapor pressures will be collected at the top of
the column, while those with higher boiling points and lower vapor pressures will be collected at
the bottom. The separated products can then be further purified or processed as necessary to meet
the desired specifications.

Therefore, multicomponent distillation involves the vaporization of a feed mixture, the separation
of the components based on their relative volatility, the condensation of the vapor, and the
collection of the separated products. The process requires careful attention to the feed preparation,
optimization of the distillation column design, and control of the operating conditions to achieve
the desired degree of separation and product purity.
Case study -

I. Benzene-Toluene-Xylene Separation: A common application of multicomponent

distillation is the separation of benzene, toluene, and xylene (BTX) from a hydrocarbon
feed mixture. The feed mixture is composed of 60% benzene, 30% toluene, and 10%
xylene. The feed flow rate is 1000 kg/hr, and it is fed to the distillation column at 30°C.
The distillation column has 20 trays and a diameter of 1 meter. The reflux ratio is set at
2:1, and the operating pressure is maintained at 1 atm. The feed is introduced at the middle
of the column, and the reboiler temperature is set at 100°C. The feed is heated in the
reboiler and introduced into the distillation column. As the mixture rises up the column,
the most volatile component, benzene, vaporizes first and rises to the top of the column.
Toluene and xylene follow, and their concentrations decrease as the mixture rises up the
column. At the top of the column, the vapor is cooled and condensed back into a liquid,
which is collected in a condenser. The liquid is then separated into individual products
based on their relative volatility. Benzene is collected at the top of the column, toluene is
collected in the middle, and xylene is collected at the bottom. The separated products are
then further purified and processed as necessary to meet the desired specifications. With
proper design, optimization, and operation, it is possible to achieve a high degree of
separation between the components and produce high-purity products at a reasonable cost.

II. Ethanol-Water Separation: Ethanol is commonly produced by fermentation of sugar-

containing crops, which results in a dilute aqueous solution of ethanol. Multicomponent
distillation is used to separate ethanol from water to obtain the desired concentration of
ethanol. The separation is challenging due to the azeotropic behavior of ethanol and water.
However, the use of a third component, such as benzene or cyclohexane, can break the
azeotrope and improve the separation efficiency.

III. Isomer Separation: Isomer separation is another application of multicomponent

distillation. For example, n-butane and isobutane are isomers that have similar boiling
points, making separation by simple distillation difficult. A multicomponent distillation
process can be used to separate the two isomers by using a series of columns, each designed
to separate a specific component. The process can be optimized by adjusting the column
pressures and temperatures to improve separation efficiency.

IV. Natural Gas Processing: Natural gas is a mixture of methane, ethane, propane, and other
hydrocarbons. Multicomponent distillation is used to separate these components for use in
different applications. The process involves a series of distillation columns, each designed
to separate a specific component. The separation is challenging due to the similarity in
boiling points and the formation of azeotropes. However, the use of refrigeration,
absorption, or membrane separation can improve the separation efficiency.
V. Petroleum Refining: Multicomponent distillation is widely used in petroleum refining to
separate crude oil into various products, such as gasoline, diesel, and jet fuel. The
separation process involves a series of distillation columns, each designed to separate a
specific fraction of crude oil based on its boiling point range. The process is challenging
due to the large number of components and their varying boiling points. However, the use
of advanced distillation technologies, such as divided-wall columns or thermal coupling,
can improve the separation efficiency.

VI. Pharmaceutical Industry: Multicomponent distillation is used in the pharmaceutical

industry to separate and purify various chemicals and drugs. The process involves a series
of distillation columns, each designed to separate a specific component or impurity. The
separation is challenging due to the complexity of the mixtures and the need for high purity
products.
Challenges & Solutions in Multi-Component Distillation : -

I. Complex Vapor-Liquid Equilibria (VLE): Multi-component systems often exhibit

complex phase behavior due to interactions between different components. This results in
non-ideal VLE, such as azeotropes or close-boiling mixtures, which can make separation
more challenging. Engineers need to understand and model these equilibria accurately to
design appropriate distillation systems.
II. Energy Efficiency: Distillation is an energy-intensive process, and multi-component
distillation can be particularly demanding. Separating multiple components with different
boiling points requires multiple stages and energy input. Engineers aim to optimize the
design and operation of distillation systems to minimize energy consumption, through
strategies such as heat integration, advanced heat exchanger networks, and energy-efficient
column configurations.
III. Column Configuration and Design: Selecting the appropriate column configuration is
crucial for multi-component distillation. Engineers need to consider factors such as the
number of trays, column diameter, feed locations, and reflux ratios. Additionally, the
presence of azeotropes or close-boiling mixtures may require additional equipment, such
as entrainers or auxiliary columns, to achieve the desired separation. Designing an efficient
and cost-effective column configuration is a significant challenge.
IV. Control and Optimization: Multi-component distillation systems are inherently complex,
making control and optimization challenging. Effective control strategies are necessary to
maintain product quality, handle variations in feed composition and flow rates, and
optimize the separation process. Advanced control techniques, such as model predictive
control (MPC), can be employed to improve the stability, efficiency, and flexibility of
multi-component distillation.
V. Dynamic Behavior: Multi-component distillation systems often experience dynamic
behavior due to disturbances, such as changes in feed composition or flow rates. These
dynamic responses can affect product purity, column stability, and overall process
efficiency. Engineers need to understand and analyze the dynamic behavior of the system
to design appropriate control strategies and ensure stable and robust operation.
VI. Process Safety: Multi-component distillation involves handling flammable, toxic, or
reactive components, posing process safety challenges. Designing and operating
distillation systems to ensure safe handling of these substances, preventing overpressure,
thermal runaway, or hazardous reactions, requires careful consideration of process safety
measures, including relief systems, emergency shutdowns, and hazard analysis.
VII. Sustainability and Environmental Impact: In today's context, sustainability and
environmental considerations play a vital role in process design. Multi-component
distillation processes should strive for reduced energy consumption, waste generation, and
emissions. Engineers need to explore novel separation techniques, process intensification,
and alternative solvents or separation agents to improve the sustainability and minimize
the environmental impact of multi-component distillation processes.
 Applications in multicomponent distillation : -

I. Petroleum refining: Multicomponent distillation is used in the refining of crude oil to

separate the various hydrocarbon components based on their boiling points. This is critical
for producing high-quality gasoline, diesel fuel, and other products.
II. Chemical manufacturing: Multicomponent distillation is used in the production of a wide
range of chemicals, such as solvents, polymers, and pharmaceuticals. Distillation is used
to separate the desired components from complex mixtures, such as reaction products or
waste streams.
III. Food and beverage production: Multicomponent distillation is used in the production of
alcoholic beverages, such as whiskey and brandy, to separate the desired flavor and aroma
compounds from the fermented mash.
IV. Environmental remediation: Multicomponent distillation is used in the treatment of
contaminated soils and groundwater to separate and concentrate the pollutants for disposal
or further treatment.
V. Polymer production: Multicomponent distillation is used in the production of polymers,
such as polyethylene and polypropylene, to separate and purify the monomers before they
are polymerized.
VI. Natural gas processing: Multicomponent distillation is used in the processing of natural gas
to separate and purify the various components, such as methane, ethane, propane, and
butane.
VII. Renewable energy production: Multicomponent distillation is used in the production of
biofuels, such as ethanol and biodiesel, to separate and purify the desired components from
the fermentation or extraction process.
Conclusion : -

Multi-component distillation poses several challenges that need to be addressed for

efficient and cost-effective separation processes. Complex Vapor-Liquid Equilibria (VLE) in
multi-component systems require accurate modeling and understanding. Energy efficiency is a key
concern, and strategies such as heat integration and advanced heat exchanger networks can help
minimize energy consumption. Selecting the appropriate column configuration is crucial for
successful multi-component distillation.

Control and optimization techniques, such as model predictive control (MPC), are
essential for stable and efficient operation. Dynamic behavior of the system should be considered,
and appropriate control strategies should be implemented to handle disturbances. Process safety
measures are critical to ensure safe handling of flammable, toxic, or reactive components.

Sustainability and environmental impact should be considered, with a focus on

reducing energy consumption, waste generation, and emissions. Ongoing research and
advancements in process simulation, optimization, and control contribute to improving multi-
component distillation processes.
References : -

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