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Energy analysis of distillation units in the process of yeast and alcohol

production

Aleksandar Anastasovski*
Ss Cyril and Methodius University
Faculty of Technology and Metallurgy, Skopje, Macedonia
email: AleksandarA@t-home.mk

Vera Meško
Ss Cyril and Methodius University
Faculty of Technology and Metallurgy, Skopje, Macedonia
email: ameshko@t-home.mk

Predrag Rašković
University of Nis
Faculty of Technology, Leskovac, Serbia
email: pr.raskovic@sezampro.yu

Liljana Markovska
Ss Cyril and Methodius University
Faculty of Technology and Metallurgy, Skopje, Macedonia
email: markovska@tmf.ukim.edu.mk

ABSTRACT
This paper reports a simulation analysis of energy consumption in steam distillation units,
which are used as a part of manufacture in the factory for yeast and alcohol production.
Distillation units are stored in the final stage of alcohol manufacture route following the
anaerobic fermentation processes. The main products of distillation process are: 96% Vol.
ethyl alcohol and technical alcohol, which presents the mixture of ethanol, aldehydes and
some other less volatile components than ethanol. Distillery is consisting of columns in
series. First of them is distillation column, but other are rectification columns. Their work
parameters are determined by inlet feed composition. When composition is not changing a
lot, whole distillation system is close to steady state. Flow, temperature and pressure are
parameters for monitoring.
The simulation analysis has been made by simulation software Aspentech HYSYS. The
validity of the model in terms of mass flow rate, temperature and pressure was examined
using actual plant data at steady-state conditions. Comparison between model results and
plant data shows good consistency and enabled the retrofit design with improved efficiency
of the unit.

Keywords: Aspentech Hysys, process simulation, ethanol, distillation

1. INTRODUCTION
Last few decades increase software using for simulation of production facilities with
improving their work [1]. There are many types of software that are in use these days. Some
of them are specialized for some specific processes in chemical technology, but some of them

*
Corresponding author: Aleksandar Anastasovski, e-mail: AleksandarA@t-home.mk
have wide field of possibilities. Using of simulation software becomes very useful in many
critical areas. Software can predict some problems that could become, finding solutions for
any case, upgrading of present process with choosing the right project proposed solution,
predict of process dynamics in case of inlet disturbance and many other features. So,
simulation software become great solution in process complexity, such as uncertainly,
dynamic behaviour and its feedback. There are developed algorithms which could be used for
exploring and optimizing the real process with this kind of software [2].

2. BASE CASE: THE SEPARATION PROCESS


This work is based on previous edited works. That works [3], [4], describe distillery - real
production system as subsystem of yeast and alcohol factory production process.

2.1 Description of the distillation system


Alcoholic fermentation is natural process where sucrose and other simple sugars are
transforming in ethanol. Enzymes that are produced by different kind of industrial yeasts
(such as Saccharomyces cerevisiae, Saccharomyces vini, etc.) are initiators for starting of
alcoholic fermentation process. Alcoholic wort is the final product of that fermentation. It is
mixture of ethanol, water and components that are contained in raw material as well as by-
products of the fermentation process. The main task of the production is separation of purest
potable ethyl alcohol. Distillation columns are used for its separation. The purpose of this
work is to simulate this real system for distillation using simulation software and comparing
simulation result data with the same parameters in real system.
That system is consisting of 3 distillation columns in series. Alcoholic wort (1), steam (3) and
cooling water (22) are inlet streams for this distillation system. Every column separate group
of components with similar physical and chemical characteristics at atmospheric pressure of
work. The first component group represent solid particles and components with high point of
evaporation, such as sugars, proteins and water. First column (DC-100, figure 2) is designed
for working conditions with higher temperatures. There is crude separation of heavy and light
phase. Inlet stream (feed inlet) as alcoholic wort is heated directly with steam. Heating cause
forming of vapour (light phase) and liquid (heavy phase). Light phase contain our product,
that is interesting for production. Heavy phase is going out throw “Silage” stream on the
bottom of the column. Light components are condensed in series of heat exchangers. They go
out throw the stream 6 (Figure 1) on the column top. First heat exchanger is using inlet
alcoholic wort (1) for cooling of light components. That process use heat to prepare alcoholic
wort to appropriate temperature (2) for feeding the column. Three heat exchangers in series
(HE-100, HE-101, and HE-102) are shell and tube heat exchangers, in vertical position with
connection for outlet of gaseous and liquid phase (phase separation). Specific construction of
heat exchangers to separate gaseous and liquid phase determine connections between
exchangers. Gaseous phase (7) is going to the next heat exchanger and liquid phase (38) is
mixing with other liquid phases condensed in other heat exchangers at atmospheric pressure
(open pipe). The same is for second and third heat exchanger with exception for third, where
connection for gaseous phase is vent to the atmosphere. Vent stream (44) contain gases that
are present in alcoholic wort. They are formed in process of fermentation, such as CO2. All
summarized condensates from all heat exchangers are mixed in “MIX – 100” and form new
stream (9) that is inlet for second column in series. All three columns have similar cooling
system as first one. Cooling in second and third heat exchanger as well as other cooling
systems for other columns is done with cooling water.
Figure 1. Graphical presentation of distillation system for ethanol production

Great parts of component that have temperature of evaporation lower then ethanol are
separated in second column. All of them are contained in top outlet stream (10) in column
DC-101. The main components of that stream are acetaldehyde and ethanol. Ethanol is
present because of component molecules interaction. Condensate of first heat exchanger is
consisting partially of heavy components. It return back to the column and is known as reflux
(11). All other condensates (18) are collected in tank for technical alcohol storage. Bottom
outlet stream from column DC-101 (13) is feeding stream for column DC-102. Column DC-
101 is positioned higher then column DC-102, so there is not need pump for enforces the
flow. That stream contains different kind of alcohols and organic acids present in alcoholic
wort. Their separation is the aim of third rectification column DC-102.
Heavy components like water and acetic acid from column DC-102 are separated and
transported with outlet stream from the bottom of the column named “Luter” (21). It has the
highest operating temperature and pressure in this column. Separated components are more
evaporative than ethanol at the top of column. That stream (16) is going to technical alcohol
storage tank. Better purification of ethanol depends by fusel oil separation as well as
separation of other present impurities. Fusel oils (32) are mixture of higher alcohols. They are
taken from trays where its concentration is highest. This alcohol mixture has specific
properties when this mixture is dissolved in water at appropriate concentration. In that case,
layer of non soluble components are formed on the top. So, decanting is appropriate method
for its separation. Decanted stream (34) takes them and transport to place for them. Soluble
part (35, 50, and 51) is going back to the column DC-102. Potable alcohol (19) is taken from
the tray with little bit lower temperature then temperature of ethanol boiling. In that tray
concentration of ethanol is maximal, because it is azeotropic mixture ethanol – water (96%
vol. ethanol). That stream is cooled and transported to the potable alcohol storage tank.
3. MODEL DEVELOPMENT ON ASPEN HYSYS PLATFORM
ASPENTECH HYSYS software is CAD/CAM type of software. It interactively changes
whole simulated system in case to change some of inputted parameters. Simulation method is
consisting of few steps. That is described in further text for distillation system simulation
model development. Hyprotech (Aspentech now) is a leader in the area of process simulation.
This technology is possible to have tremendous impact on not only the way that engineers
approach control strategy development, but on how we approach modelling in general [5].

3.1 Method of distillery simulation


Simulation model of distillery using software is done in few steps. As first step is input of
basic data for the system. That means input of components (software data base) and choosing
of thermodynamic model that will be used for simulation of component`s physical and
chemical characteristics. Components that are present in distillation system are: ethanol,
propanol-2, buthanol-2, glycerol, acetic acid, lactic acid, pyruvic acid, ethyl acetate,
acetaldehyde, H2S, CO2, water and air. NRTL (Non Random Two Liquid) is thermodynamic
model that was chosen for this simulation. This simulation case is without chemical reactions.
All processes are based on physical characteristics of present components. Equitation (1) is
basic NRTL for binary system. Every of parameters are determined with equations (2) and
(3) [6].
GE G21 21 G1212
  (1)
x1 x2 RT x1  x2G21 x2  x1G12
G12  exp   12 
(2)
G21  exp   21 
b12
 12 
RT
(3)
b21
 21 
RT
There are three specific parameters ∝, b12 and b21 that are not depend of composition and
temperature. They are specific to a particular pair of species. Multi component systems use
this equitation, but it is more complex. It depends on number of components.
Next step is starting simulation environment with adding system`s inlet stream (1). After that
is starting with adding of equipment step by step as process is going to be done.

Figure 2. The first column with its cooling system, part of distillation system
Heat exchangers – (Figure 2) are determined with inlet and outlet streams, temperatures,
pressures and flows of those streams, heat exchanger type, number of tubes, diameter, tube`s
position, shell diameter, pipe connection in fluid flow spaces, material of construction,
fouling factor, horizontal or vertical position of HE (all that for tube and shell type of heat
exchanger), pressure drop in shell side and tube side. These are parameters that specify all
heat exchangers in this system. There are three heat exchangers in series specified for the first
column that are cooling top outlet stream. Cooling fluid for the first heat exchanger is
alcoholic wort as the main feed of the system. Cooling water with specific characteristics is
used for cooling in other two heat exchangers. These heat exchangers are positioned
vertically and have duty to cool the top outlet stream as well as phase separation. Simulation
model need phase separation. There is added phase separator to every heat exchanger outlet.
So, phase separators separate gases and send them to the other following heat exchanger of
the series. All liquid phases, separated after heat exchangers are sent to mixer with aim to
form new stream that will feed second column. Mixer is specified to take the lowest pressure
of streams (atmospheric pressure). Phase separators are specified to separated phases in
conditions that they leave heat exchangers. All heat exchangers are positioned on higher level
of columns, so streams not need pumps, but in simulation model pump must be added to
simulate that pressure by higher level position. The last heat exchanger in series needs to
have outlet to the atmosphere, where separated CO2 and air is going. That gases are coming
from alcoholic wort, where are formed in process of fermentation. They are separated in
correct operation of distillery.
Mixing of three streams with different temperatures provoke small evaporation. That is
simulated with phase separator, where (47) is stream of evaporation. Quantities are very
small.
Distillation column 1 (DC-100) – (Figure 2) the basic specifications that are need for column
specification are: number of trays, high and diameter of trays, high of tray`s overflow, type of
trays, temperature and pressure on the top and on the bottom of column, feeding stream inlet
tray, specified trays for outlet streams, as well as the tray of steam inlet. This is case with
directly injection of steam in column, so pressure and temperature of steam are very
important. Quantity of steam that is need for column is interactively determined. Tray
efficiency coefficient is needed to be input. It is used to be determined by the results of
simulation. Physical and chemical characteristics of outlet streams (6) and (5) are simulation
values. Those values are used in further simulation of process.
Distillation column 2 (DC-101) – This column (Figure 3) need all specifications given for
determination of the first column in series, but also need some new specifications. This
column has reflux, so that kind of equipment is chosen. The first heat exchanger is contained
into the column as one equipment unit. That means simulation of two heat exchangers in
series. Reflux ratio is important specification for this column.
Figure 3. The second and third columns in series, part of distillation system

Distillation column 3 (DC-102) – This is the most complicated part of simulation of this
system (Figure 3). There are few inlet, outlet and recycled streams. Basically, this column is
determined as other two, but there are added new specifications such as outlet and inlet
stream`s tray number, reflux ratio and flows of outlet streams. Number of specifications is
equal to number of freedom degree of the column. That must satisfy to be zero degree. One
of streams is going out to be purified. After its purification the pure components are going
back to the column. That is (32) stream. It is solving with water (33) in online mixer for two
streams. Component splitter X-100 is used for decanting simulation. Component splitter is
specified to split defined components and with determined efficiency. One outlet stream is
going to drainage with fusel oils (34); other (50) is going back to the column DC-102.
Recycling stream is simulating with logic connectors. That kind is connector for recycling
RCY-1 (Figure 3). There are specified returning conditions of stream, such as temperature,
pressure and flow.
Potable alcohol stream, technical alcohol stream and fusel oils coolers are determined as all
other heat exchangers. Cooling water is used as cooling medium.
There are also made comparation of steam and cooling needs for changing of flow. This
simulation model is used for this comparation and simulated situation of variables is used as
referent values presented as 100% (100% of variable value). This comparation is made to be
determined the optimal energy need for this plant. The main preferences are:
- Column temperature and pressure profile is not changing
- Steam and cooling fluid characteristics are the same
- Ethanol concentrations are the same in every part of plant
- Feeding fluid, steam mass flow and energy taken from coolers are changed
The basic idea of this analysis is determination of optimal work of distillation plant.
4. RESULTS AND DISCUSSION
Results that are calculated with software and the values of real distillation system are
compared. Error analysis is done. Deviations are represented in Table 1. According to
represented data, values of simulated parameters and parameters in real system are evidently
close. This prepared simulation model of distillery could be used for further estimation of
system. That means estimation of energy that would be needed for any change in distillery
operating and estimation of equipment before doing correction in some part of system.
Alcoholic wort composition deviation could be one of disturbances of the system. Changing
of alcoholic wort composition could be happened as a result of fermentation problems.
This model could be also used for upgrade of present system with new equipment and its
design and efficiency estimation.
Table 1. Deviation between simulated and real values of distillery system parameters (error analysis)

Stream Pressure deviation (%) Temperature deviation (%) Flow deviation (%)
4 2,000 0,310 2,315
14 1,960 1,163 26,666
15 4,761 0,661 7,894
5 10,775 0,588 0,689
1 0,542 0,000 0,184
2 0,732 0,000 0,184
6 2,316 0,795 20,463
7 2,316 13,841 11,583
9 4,735 4,666 11,196
10 2,316 1,273 13,647
11 2,316 7,246 8,080
16 2,316 0,000 6,944
17 2,316 0,000 13,157
18 2,316 1,550 24,000
19 0,886 7,977 31,654
20 0,886 0,000 31,654
21 4,166 0,582 36,398
13 13,846 5,654 24,769

With this analysis, we approved the simulation model. So, we can try theoretically to determine
optimal working state of plant. There are rewieved 5 cases. Case no. 3 is simulation model. Other
cases are simulation of 50%, 75%, 125% and 150% of feeding flow value in case No.3. So, values of
steam in every column, as well as total steam needed for every case are relative value of steam needs
in case No.3. The same is used for cooling needs. The results are shown in table 2 and 3. The
graphical presentation of results are given on Figures 4, 5, 6 and 7.
Table 2. Simulation results for every column separately

Case % of % of % of % of % of % of % of % of
feed flow steam cooling steam steam cooling Technical Potable Alc.
needs (DC-100) needs needs (DC-101, Alc.flow flow
(DC-100) (DC- (DC- DC-102)
101) 102)
1 150 152 168,67 200,00 136,73 142,76 155,17 150
2 125 127 142,79 166,67 114,29 119,16 130,20 125
3 100 100 100,00 100,00 100,00 100,00 100,00 100
4 75 75 75,21 93,33 67,35 69,78 74,73 75
5 50 50 50,15 73,33 44,90 47,45 50,54 50

Table 3. Total steam and cooling need of distillation plant determined with simulation

Case % of feed % Total steam % Total % Total steam % Total cooling


flow cooling per produced per produced
Potable alcohol Potable alcohol
1 150 149,06 145,60 99,37 97,07
2 125 124,53 121,75 99,62 97,40
3 100 100,00 100,00 100,00 100,00
4 75 73,33 70,38 97,78 93,84
5 50 49,31 47,75 98,62 95,49

Figure 4. Presentation of percentage of feeding Figure 5. Comparation of total steam and total
flow, steam and cooling needs for every case cooling per unit of produced potable alcohol
compared with case No. 3
Figure 6. Funcion of total steam needs per Figure 7. Funcion of total cooling needs per
product per case (better minimum product per case (better minimum
determination) determination)

Results shown on table 4 are expected and proportional to feeding flow. Otherwise, total results and
especially total steam and total cooling per product give us good data for optimization. In comparation
of all cases, case No. 4 needs minimum energy and cooling. That is optimal case of plant working.
The values are close, so there are 3% lower steam needs and 6% lower cooling needs.

CONCLUSION

Preparing of simulation model for some production plant could predict way of plant working.
Theoretically could be predicted optimal needs of energy. The next step of this theoretically
prediction is practically aprovement.

REFERENCES

1. Ruiz Mercedes, Ramos Isabel, Toro Miguel, “A Dynamic Integrated Framework for
Software Process Improvement”; Software Quality Journal 10, 181-194, 2002
2. Nissen Mark E., “An Intelligent Tool for Process Redesign: Manufacturing Supply-
Chain Applications”; The International Journal of Flexible Manufacturing Systems,
12 (2000): 321 – 339
3. A.Anastasovski, L. Markovska, V. Meshko, Heat integration of ethanol and yeast
manufacture, Macedonian Journal of Chemistry and Chemical Engineering, 26(2)
2007
4. Rašković P., Anastasovski A., Markovska Lj., Meško V. “Process integration of yeast
fermentation plant” , ECOS 2008 – Krakow, Poland
5. Mahoney, Donald P., Fruehauf, Paul S., “An Integrated approach for distillation
column control design using steady state and dynamic simulation” (2009) URL:
http://www.aspentech.com/publication_files/An_Integrated_Approach_for_Distillatio
n_Column_Control.pdf
6. Perry Robert H, Green Don W., Perry`s Chemical Engineers Handbook McGraw Hill
Companies Inc. 1999
APENDIX 1

Table A1. Description of streams shown on figures 1, 2 and 3

Stream Stream description Stream Stream description


number number
1 Distillery feed 28 Cooling water HE- 104 outlet
2 Feed of DC-100 28` Cooling water DC-102 outlet
3 Main steam distillery feed 29 Cooling water HE- 103 outlet
4 Steam for DC-100 29` Cooling water HE- 103 outlet
(simulation)
5 Silage 30 Cooling water HE- 102 outlet
6 DC-100 top outlet 30` Cooling water HE- 102 outlet
(simulation)
7 HE-101 inlet 31 Total outlet of cooling water
8 DC-100 Reflux 32 Fusel oil (hot)
9 DC-101 feed 32` Fusel oil (cooled)
10 DC-101 top outlet 33 Water for fusel oil dissolve
11 DC-101 reflux 34 Decanted Fusel oil
12 Technical alcohol part 1 35 Recycled stream – fusel oil free
13 DC-103 feed 36 Cooling water HE- 105 inlet
14 Steam for DC-101 37 Cooling water HE- 105 outlet
15 Steam for DC-102 38 Condensate HE-100
16 Technical alcohol part 2 (hot) 39 Separated gas in HE-100
16` Technical alcohol part 2 (cooled) 40 HE-101 outlet
17 DC-103 reflux 41 Condensate HE-101
18 Technical alcohol (total) 42 Separated gas in HE-101
19 Potable alcohol (hot) 43 HE-102 outlet
20 Potable alcohol (cooled) 44 Gas exit
21 Luter 45 Condensate HE-102
22 Cooling water – distillery feed 46 Mixed condensates
23 Cooling water HE- 106 inlet 47 Gas exit from mixer
24 Cooling water HE- 104 inlet 48 Total liquid condensated from DC-100
25 Cooling water HE- 103 inlet 49 Solved fusel oils
26 Cooling water HE- 101/102 inlet 50 Separated fusel oil free stream –
simulation
26` Cooling water HE- 102 inlet 51 Pressurized recycled stream -
simulation
27 Cooling water HE- 106 outlet

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