See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/322342951

Advanced Distillation Technologies: Design, Control and Applications

Book · April 2013

DOI: 10.1002/9781118543702

CITATIONS READS

206 4,563

1 author:

Anton A. Kiss
Delft University of Technology
326 PUBLICATIONS 8,876 CITATIONS

SEE PROFILE

All content following this page was uploaded by Anton A. Kiss on 23 January 2019.

The user has requested enhancement of the downloaded file.

Advanced Distillation
Technologies
Design, Control and Applications

Anton Alexandru Kiss

Contents

Preface xiii

Acknowledgements xv

1 Basic Concepts in Distillation 1

1.1 Introduction 1
1.2 Physical Property Methods 2
1.3 Vapor Pressure 6
1.4 Vapor–Liquid Equilibrium and VLE Non-ideality 8
1.4.1 Vapor–Liquid Equilibrium 8
1.4.2 VLE Non-ideality 11
1.5 Relative Volatility 13
1.6 Bubble Point Calculations 14
1.7 Ternary Diagrams and Residue Curve Maps 16
1.7.1 Ternary Diagrams 16
1.7.2 Residue Curve Maps 18
1.8 Analysis of Distillation Columns 24
1.8.1 Degrees of Freedom Analysis 26
1.8.2 McCabe–Thiele Method 27
1.8.3 Approximate Multicomponent Methods 33
1.9 Concluding Remarks 34
References 35
2 Design, Control and Economics of Distillation 37
2.1 Introduction 37
2.2 Design Principles 38
2.2.1 Operating Pressure 39
2.2.2 Heuristic Optimization 40
viii CONTENTS

2.2.3 Rigorous Optimization 41

2.2.4 Feed Preheating 42
2.2.5 Intermediate Reboilers and Condensers 42
2.2.6 Heat Integration 43
2.3 Basics of Distillation Control 44
2.3.1 Single-End Control 46
2.3.2 Dual-End Control 49
2.3.3 Alternative Control Structures 52
2.3.4 Constraint Control 53
2.3.5 Multivariable Control 54
2.4 Economic Evaluation 55
2.4.1 Equipment Sizing 56
2.4.2 Equipment Cost 59
2.4.3 Utilities and Energy Cost 62
2.4.4 Cost of Chemicals 63
2.5 Concluding Remarks 63
References 64

3 Dividing-Wall Column 67
3.1 Introduction 67
3.2 DWC Configurations 70
3.3 Design of DWCs 75
3.3.1 Heuristic Rules for DWC Design 77
3.3.2 Approximate Design Methods 78
3.3.3 Vmin Diagram Method 79
3.3.4 Optimal Design of a DWC 82
3.4 Modeling of a DWC 83
3.4.1 Pump-Around Model 84
3.4.2 Two Columns Sequence Model 84
3.4.3 Four Columns Sequence Model 85
3.4.4 Simultaneous Models 86
3.4.5 Simulation of a Four-Product DWC 86
3.4.6 Optimization Methods 86
3.5 DWC Equipment 87
3.5.1 Liquid/Reflux Splitter 89
3.5.2 Column Internals 91
3.5.3 Equipment Sizing 91
3.5.4 Constructional Aspects 94
3.6 Case Study: Separation of Aromatics 97
3.7 Concluding Remarks 103
References 107
CONTENTS ix

4 Optimal Operation and Control of DWC 111

4.1 Introduction 111
4.2 Degrees of Freedom Analysis 112
4.3 Optimal Operation and Vmin Diagram 114
4.4 Overview of DWC Control Structures 117
4.4.1 Three-Point Control Structure 118
4.4.2 Three-Point Control Structure with
Alternative Pairing 120
4.4.3 Four-Point Control Structure 121
4.4.4 Three-Point Control Structure with
Nested Loops 121
4.4.5 Performance Control of Prefractionator
Sub-system using the Liquid Split 122
4.4.6 Control Structures Based on Inferential
Temperature Measurements 123
4.4.7 Feedforward Control to Reject Frequent
Measurable Disturbances 126
4.4.8 Advanced Control Techniques 127
4.5 Control Guidelines and Rules 128
4.6 Case Study: Pentane–Hexane–Heptane Separation 129
4.7 Case Study: Energy Efficient Control of a BTX DWC 132
4.7.1 Energy Efficient Control Strategies 135
4.7.2 Dynamic Simulations 139
4.8 Concluding Remarks 148
References 149

5 Advanced Control Strategies for DWC 153

5.1 Introduction 153
5.2 Overview of Previous Work 154
5.3 Dynamic Model of a DWC 156
5.4 Conventional versus Advanced Control Strategies 163
5.4.1 PID Loops within a Multi-loop Framework 163
5.4.2 Linear Quadratic Gaussian Control 165
5.4.3 Generic Model Control 167
5.4.4 Multivariable Controller Synthesis 167
5.5 Energy Efficient Control Strategies 171
5.5.1 Background of Model Predictive Control 173
5.5.2 Controller Tuning Parameters 175
5.5.3 Dynamic Simulations 176
5.6 Concluding Remarks 180
x CONTENTS

Notation 181
References 183

6 Applications of Dividing-Wall Columns 187

6.1 Introduction 187
6.2 Separation of Ternary and Multicomponent Mixtures 188
6.3 Reactive Dividing-Wall Column 195
6.4 Azeotropic Dividing-Wall Column 198
6.5 Extractive Dividing-Wall Column 199
6.6 Revamping of Conventional Columns to DWC 203
6.7 Case Study: Dimethyl Ether Synthesis by R-DWC 205
6.8 Case Study: Bioethanol Dehydration by A-DWC and
E-DWC 212
6.9 Concluding Remarks 223
References 223

7 Heat Pump Assisted Distillation 229

7.1 Introduction 229
7.2 Working Principle 231
7.3 Vapor (Re)compression 232
7.3.1 Vapor Compression 233
7.3.2 Mechanical Vapor Recompression 233
7.3.3 Thermal Vapor Recompression 234
7.4 Absorption–Resorption Heat Pumps 234
7.4.1 Absorption Heat Pump 234
7.4.2 Compression–Resorption Heat Pump 235
7.5 Thermo-acoustic Heat Pump 236
7.6 Other Heat Pumps 240
7.6.1 Stirling Cycle 240
7.6.2 Vuilleumier Cycle 241
7.6.3 Brayton Cycle 241
7.6.4 Malone Cycle 242
7.6.5 Solid–Sorption Cycle 242
7.7 Heat-Integrated Distillation Column 244
7.8 Technology Selection Scheme 245
7.8.1 Energy Efficient Distillation
Technologies 246
7.8.2 Multicomponent Separations 249
7.8.3 Binary Distillation 254
7.8.4 Selected Scheme Applications 263
CONTENTS xi

7.9 Concluding Remarks 265

References 265

8 Heat-Integrated Distillation Column 271

8.1 Introduction 271
8.2 Working Principle 273
8.3 Thermodynamic Analysis 277
8.4 Potential Energy Savings 280
8.4.1 Partial Heat Integrated Distillation Column
(p-HIDiC) 280
8.4.2 Ideal Heat Integrated Distillation Column
(i-HIDiC) 281
8.5 Design and Construction Options 282
8.5.1 Inter-coupled Distillation Columns 284
8.5.2 Distillation Column with Partition Wall 285
8.5.3 Concentric Distillation Column 287
8.5.4 Concentric Column with Heat Panels 288
8.5.5 Shell & Tube Heat-Exchanger Column 289
8.5.6 Plate-Fin Heat-Exchanger Column 290
8.5.7 Heat Transfer Means 292
8.6 Modeling and Simulation 295
8.7 Process Dynamics, Control, and Operation 297
8.8 Applications of HIDiC 300
8.9 Concluding Remarks 304
References 305

9 Cyclic Distillation 311

9.1 Introduction 311
9.2 Overview of Cyclic Distillation Processes 313
9.3 Process Description 316
9.4 Mathematical and Hydrodynamic Model 319
9.4.1 Mathematical Model 319
9.4.2 Hydrodynamic Model 321
9.4.3 Sensitivity Analysis 323
9.5 Modeling and Design of Cyclic Distillation 327
9.5.1 Modeling Approach 329
9.5.2 Comparison with Classic Distillation 331
9.5.3 Design Methodology 331
9.5.4 Demonstration of the Design Procedure 333
9.6 Control of Cyclic Distillation 335
xii CONTENTS

9.7 Cyclic Distillation Case Studies 338

9.7.1 Ethanol–Water Stripping and Concentration 338
9.7.2 Methanol–Water Separation 341
9.8 Concluding Remarks 347
References 349

10 Reactive Distillation 353

10.1 Introduction 353
10.2 Principles of Reactive Distillation 354
10.3 Design, Control and Applications 357
10.4 Modeling Reactive Distillation 362
10.5 Feasibility and Technical Evaluation 364
10.5.1 Feasibility Evaluation 364
10.5.2 Technical Evaluation 367
10.6 Case Study: Advanced Control of a Reactive
Distillation Column 371
10.6.1 Mathematical Model 371
10.6.2 Open-Loop Dynamic Analysis 374
10.6.3 Closed-Loop Performance 374
10.7 Case Study: Biodiesel Production by
Heat-Integrated RD 378
10.8 Case Study: Fatty Esters Synthesis by Dual RD 383
10.9 Concluding Remarks 387
References 388

Index 393
Preface

Our modern society is currently facing an energy revolution, and it needs

to identify properly the potential threats and use all the opportunities to
meet the needs of the growing population. Accordingly, chemical engi-
neers have embarked on a quest for shaping a much needed sustainable
future—especially considering that chemical industry is among the most
energy demanding sectors. Distillation is a thermal separation method
widely applied in the chemical process industry as the separation tech-
nology of choice, despite its very low thermodynamic efficiency. Remark-
ably, almost every single product on the market includes components that
went through a distillation column. Even now, when changing from fossil
fuels to a bio-based economy, it is clear that in the next two decades
distillation will retain its significance as the main method for separating
mixtures—although this old workhorse of the chemical industry is facing
some new big and bold challenges.
Owing to the limitation of fossil fuels, the need for energy indepen-
dence, and the environmental problem of the greenhouse gas effect, there
is a considerable increasing interest in the research and development of
integrated chemical processes that require less capital investment,
reduced operating costs, and have high eco-efficiency. Energy efficient
distillation is a hot topic in separation technology due to the key
advantages of the integrated technologies, such as reduced investment
costs and low energy requirements, as well as an increasing number of
industrial applications. Although the research and development carried
out at universities and industrial companies in this exciting field is
expanding quickly, there is still no book currently available focusing
on this important area in distillation technology—the largest consumer of
energy in the chemical process industry.
 xiv PREFACE

Therefore, we feel that there is a significant gap that can be addressed

with this book and it will be of immense interest to a readership across the
world. The book provides engineers with a wide and relatively deep
insight into integrated distillations using non-conventional arrange-
ments. Readers can learn from this material the background, recent
developments, fundamental principles, design and simulation methods,
detailed case studies of distillation processes, as well as expected future
trends. We believe that the abundant valuable resources included here—
relevant equations, diagrams, figures, and references that reflect the
current and upcoming integrated distillation technologies—will be of
great help to all readers from the (petro-)chemical industry, bio-refineries,
and other related areas.
This book is the first comprehensive work about advanced distillation
technologies, covering many important topics such as key concepts in
distillation technology, principles of design, control, equipment sizing
and economics of distillation, DWC design and configurations, optimal
operation, controllability and advanced control strategies, industrial and
pilot-scale DWC applications (in ternary separations, azeotropic distil-
lation, extractive distillation, and reactive distillation), HIDiC design and
configurations, heat pump assisted applications, cyclic distillation, and
reactive distillation. Each chapter is independently written and consists
typically of an introduction, working principle, process design, modeling
and simulation, process control and operation, specific equipment,
industrial and applied research examples, concluding remarks, as well
as a comprehensive list of useful references for further reading.
Note that the author is aware about the unavoidable presence of some
minor mistakes. That is why I would like to express my gratitude for
every observation and suggestion towards further improving this
material.

View publication stats