Redesign Analysis of a Distillation Column

Presented By: Michael Hoepfner University of Utah 2006

Introduction
Why care

about redesign?

Outline
Objective Theory
Experiment

Results
Aspen Analysis

Recommendations
Conclusion /

Summary

Objective
Scope

Isopropyl Alcohol (IPA) and Water to Ethanol (EtOH) and Water

Is the switch possible? What are the limitations?

Purpose

Outline
Objective

Theory Experiment Results Aspen Analysis Recommendations Conclusion / Summary

Theory
Distillation

Is among the most common of separations Separates compounds based on volatility Utilizes multiple equilibrium separations

Theory (cont.)
T-x-y Diagram
0.7

x-y Diagram
0.65 0.6

210 205 Bubble Line

0.55

Vapor r Fraction IPA

Dew Line

Temerature (F)

0.5 0.45 0.4 0.35 0.3 0.25 0.2 0.15

200 195 190 185 180

Equilibrium Line 45 Degree Line

0.1

175 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

0.05 0 0 0.05 0.1 0.15 0.2

Mole Fraction IPA

Liquid Fraction IPA

0.25

0.3

0.35

0.4

0.45

0.5

0.55

0.6

0.65

0.7

Source: Perrys Chemical Engineering Handbook, 7th Ed.

Theory (cont.)

McCabe-Thiele

Simple and useful tool for defining a distillation column Three lines can characterize the conditions

Source: Seader, 2006

Theory (cont.)

Source: Seader, 2006

Theory (cont.)
Efficiency

Liquid samples, therefore, liquid efficiency

E ML

xi ,n 1 xi ,n xi ,n 1 x *i ,n
Source: King, 1971

Theory (cont.)

1.38 1.375 1.37

Refractive Index

1.365 1.36

Refractive Index (RI) was used to measure the concentration

1.355 1.35

1.345 1.34 1.335 1.33

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

Mole Percent IPA

Source: CRC Handbook of Chemistry and Physics, 64th Edition

Outline
Objective Theory

Experiment Results Aspen Analysis Recommendations Conclusion / Summary

Experiment

Apparatus

12 Trays with 3 inch bubble caps Total Condenser Partial Reboiler Thermal couple at every tray

Source: Ong, 1952

Experiment (cont.)
Operate

at total reflux
at 2 times the minimum reflux

Collect samples for efficiency determination Collect samples for efficiency determination

Operate

Model

results in Aspen for ethanol and

water

Outline
Objective Theory
Experiment

Results Aspen Analysis Recommendations Conclusion / Summary

Results

Obtained samples on three separate occasions Samples are numbered by the date collected

10/30/2006
First run of total reflux

11/01/2006
Second run of total reflux

11/06/2006
Only run of partial reflux

Results (cont.)
Concentration of Samples
70.0 60.0

Mole Percent IPA

Total Reflux 10/30/2006

50.0 40.0 30.0 20.0 10.0 0.0 0 1 2 3 4 5 6

Total Reflux 11/01/2006 Partial Reflux 11/06/2006

10

11

12

Tray Number

Results (cont.)

Efficiency

Total Reflux 10/30/2006 Tray

Distillate

Partial Reflux 11/06/2006 ML

-

ML
-

Error
-

ML Fixed
-

Error
-

Two reasonably reliable data sets All error is at a 95% confidence interval

2 3 4 5
6

15.7 20.2 32.4 18.6

27.0

6.5 4.1 3.1 2.5

2.0

109.8 94.9 480.3 -93.2

-7.4

0 94.9 0 0
0

156.3 -

7 8
9

97.8 91.5
0 -

0* 0*

4885.2 -84.2
82.5

0 0
82.5

125.9

10
11

0
0

492.5
132.6

0
0

12 Bottoms
Average

0 0
25.3

3.7

20.2 -113.8

20.2 0
18.0

26.0 102.8

Outline
Objective Theory
Experiment

Results

Aspen Analysis Recommendations Conclusion / Summary

Aspen Analysis

Aspen

Used average stage efficiency for every stage It is possible to do separation Limited by total condenser load
Max condenser load: 27811 kW Max reboiler load: 241020 kW

TOPSC

F EED C

C OMPLEX

BOTTC

Aspen Analysis (cont.)

Feed Flow (gpm) Upper Average Lower 7.85 7.55 7.26 Distillate Flow (kmol/hr) 20.68 19.90 19.11 Bottoms Flow (kmol/hr) 53.93 51.89 49.84 Reboiler Steam Duty Flow (kW) (kg/min) 401.09 385.96 370.70 10.58 10.18 9.78

Condenser Duty (kW) 289.19 278.29 267.27

Outline
Objective Theory
Experiment

Results
Aspen Analysis

Recommendations Conclusion / Summary

Recommendations
Ethanol separation is

possible

Max feed 7.550.30 GPM of 15 mole % ethanol Reboiler steam required 10.180.40 kg/min By redesigning the condenser, capacity can be greatly increased
Reboiler only at ~1/6th of capacity

Allow more

time for partial reflux efficiency

Outline
Objective Theory
Experiment

Results
Aspen Analysis

Recommendations

Conclusion

/ Summary

Conclusion / Summary
Redesign analysis is

an important part of

chemical processing Distillation column in senior lab is about 25.3 3.7 % efficient Ethanol and water separation is possible

Limited by the total condenser

Sources

Weast, Robert C, Editor. CRC Handbook of Chemistry and Physics, 64th Edition. CRC Press, Inc. Boca Raton, 1983. p. D-253. King, C. Judsen. Separation Processes. McGraw-Hill, New York,1971. p 603. Ong, John N. Jr, Jack M. Whitney. The Operation of a Laboratory Bubble-Plate Distillation Column. University of Utah, June, 1952. Perry, Robert H., Editor. Perrys Chemical Engineering Handbook. 7th Edition. McGraw-Hill. New York, 1999. p. 115. Seader, J. D., Ernest J. Henley. Separation Process Principles, 2nd Edition. John Wiley and Sons. Hoboken, 2006. p. 193-294. Silcox, Geoff. Basic Analysis of Data. Unpublished student aid. University of Utah, 1999.

Questions?