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AJCHE 2012, Vol. 12, No.

1, 20 – 33

Synthesis of Ternary Homogeneous


Azeotropic Distillation Sequences:
Entrainer Selection
Sutijan*,1
Megan Jobson2
Robin Smith2
1
Department of Chemical Engineering, Faculty of Engineering, Gadjah Mada University, Jl.
Grafika 2 Yogyakarta, Indonesia
2
School of Chemical Engineering and Analytical Science, The University of Manchester, PO
Box 88, Sackville St, Manchester, M60 1QD, UK
*
e-mail: sutijan@chemeng.ugm.ac.id

This paper presents a methodology for automatic selection of entrainers for


separating binary azeotropic mixtures using homogeneous azeotropic distillation. A new
classification system for ternary mixtures based on the termini of distillation boundaries
and the type (stability) of products and azeotropes is proposed. The new characterisation
system is able to link candidate entrainers to flowsheet structures which can facilitate the
separation. Existing entrainer selection criteria are extended to accommodate other
promising entrainers, including light, intermediate and heavy-boiling entrainers.

Keyword: Azeotropic Distillation, Distillation Line Map, Distillation Sequence, Entrainer


Selection, Residue Curve Map, Ternary

INTRODUCTION feasibility of proposed distillation columns


and column sequences and can be used to
A third component, or entrainer, can screen potential entrainers. The two types
often allow the separation of a binary of maps are qualitatively identical (Widagdo
azeotropic mixture into two pure and Seider, 1996). Therefore they provide
components using homogeneous valuable conceptual tools for process
distillation. The vapour-liquid equilibrium synthesis, that is, for selecting a suitable
behaviour of the resulting ternary mixture entrainer, flowsheet configuration and
can be characterised using residue curve columns designs, to separate a binary
maps (RCM) or distillation line maps (DLM). mixture in the presence of an entrainer.
These two maps contain sets of feasible Doherty and Caldarola (1985) suggest a
liquid composition profiles for staged and conservative entrainer selection criterion for
packed columns, respectively, operating at the separation of a binary
total reflux. Residue curve and distillation azeotrope-forming mixture (a-b) – an
line maps are useful for assessing the entrainer is suitable if both desired products
Sutijan, Megan Jobson, and Robin Smith 21

lie in the same distillation region. Laroche et BACKGROUND


al. (1992) develop entrainer selection criteria
that accept entrainers that form curved The existing classification systems for
boundaries. This enables the use of a ternary mixtures (Matsuyama and Nishimura,
column crossing the boundary (i.e. with the 1977, and extended by Stichlmair and
feed lying in one distillation region and both Herguijuela, 1992) use singular point
products in another adjacent region) and properties to characterise the vapour-liquid
leads to a longer list of potential entrainers. equilibrium behaviour of a ternary mixture.
Stichlmair and Herguijuela (1992) and All residue curve maps and distillation line
Stichlmair and Fair (1998) propose another maps can be classified. However, the
strategy for entrainer selection, which can classification system results in a relatively
accept an entrainer that produces new large number of classes of residue curve
azeotropes with one or two of the maps or distillation line maps.
components of the binary azeotropic feed Furthermore, the classification system
mixture. cannot indicate whether or not an entrainer
However, existing classification systems will facilitate the desired separation.
for the vapour-liquid equilibrium behaviour Therefore, it is difficult to draw general
of ternary homogeneous mixtures cannot guidelines for the selection of promising
explicitly make a link between proposed entrainers based on the existing
entrainers, the feasibility of the desired characterisation systems. Unless stated
separation between the binary otherwise, this work uses distillation line
azeotrope-forming components and the maps and the classification system of
distillation sequence and recycle Stichlmair et al. (1989).
connections (flowsheet structure) that will It is usually possible to separate binary
facilitate the separation. In this work, a azeotropic mixtures into their pure
new classification system is proposed for constituents by addition of an entrainer.
this purpose. This classification method The choice of the entrainer must permit easy
characterises ternary mixtures based on the separation of the azeotrope-forming
existence and termini (i.e. end points) of components and the recovery of the
distillation boundaries in the composition entrainer, which will be recycled within the
space diagram and the type (stability) of process.
binary azeotropes and of the desired Wahnschafft et al. (1992) and
products. Associated with each entrainer Wahnschafft and Westerberg (1993) suggest
facilitating the desired separation is one or a simple method to identify promising
more flowsheets. A systematic approach to entrainers. The equilibrium constants of
linking proposed entrainers to suitable the azeotropic components at infinite
flowsheets will be presented in a further dilution in an entrainer reflect the impact of
work. the entrainer on the relative volatilities of
22 Synthesis of Ternary Homogeneous Azeotropic Distillation Sequences: Entrainer Selection

the azeotrope-forming species. Based on distillation boundary. The generalised


the equilibrium constant at infinite dilution, flowsheet contains three columns and two
Bauer and Stichlmair (1995) and Gmehling recycle streams. If the boundary is highly
and Möllmann (1998) use the selectivity of curved a two-column flowsheet can be used.
the azeotropic components at infinite The entrainer selection criteria of Doherty
dilution in the entrainer to guide entrainer and Caldarola (1985) and Stichlmair and
selection. However, neither of the Herguijuila (1992) are adopted and
proposed indicators provides information extended in this work. As will be shown,
about vapour-liquid equilibrium behaviour many entrainers which violate the existing
over the whole of the composition space. criteria can facilitate the desired separation
Two sets of criteria for entrainer selection of an a-b mixture to product pure
based on residue curve maps and distillation component products a and b. Also
line maps have been proposed. The first adopted and extended in this work are the
approach selects an entrainer that produces entrainer selection criteria of Knapp and
no boundary between the two azeotropic Doherty (1992) which include entrainers that
constituents (Doherty and Caldarola, 1985; produce pressure-sensitive distillation
Foucher et al., 1991). In this case, the boundaries.
binary azeotrope a-b, i.e. the azeotrope Rooks et al. (1998) propose the ‘common
formed between components a and b, must saddle criterion’ to identify feasible splits
be either an origin or a terminus of using a single-feed column. The feasibility
distillation lines. Van Dongen and Doherty criterion requires the high-reflux or
(1985) and Levy et al. (1985) observe that high-reboil liquid composition profiles from
the entrainer selection strategy of Doherty both products to approach the same saddle.
and Caldarola (1985) is conservative and can This criterion is a sufficient (but not
miss many potentially suitable entrainers. necessary) condition for split feasibility that
In the second approach, the entrainer is can miss other feasible splits. In particular,
selected so that the two constituents when ‘continuous distillation regions’ (Safrit
(desired products) of the binary feed and Westerberg, 1997), also known as
mixture are origins or termini of distillation ‘compartments’ (Thong, 2000) exist, feasible
lines (Stichlmair and Herguijuela, 1992; splits can be incorrectly identified as
Stichlmair and Fair, 1998). Such systems unfeasible splits. A compartment is a
always have distillation boundaries. subspace within the composition space
Additional azeotropes and even ternary which contains one stable node, an adjacent
azeotropes may exist. Based on these saddle and an adjacent unstable node.
criteria, Stichlmair and Herguijuela (1992) Within a compartment the volatility order is
propose the ‘generalised flowsheet’ for constant. The compartment is bounded by
separating the constituents of an a-b a compartment boundary, although no
minimum- or maximum-boiling azeotrope rigorous definition of the concept exists; in
using an entrainer. The generalised this work the boundary is approximated by a
flowsheet requires the distillation boundary straight line connecting the unstable and
to be curved; one of the columns crosses the stable nodes.
Sutijan, Megan Jobson, and Robin Smith 23

The set of feasibile composition profiles for ternary mixtures based on the existence
of a column section is bounded by the total and termini (beginning or end points) of
reflux and minimum reflux (reversible distillation boundaries and the stability of
operating) composition profiles singular points. This classification system
(Wahnschafft et al., 1992) i.e. the residue enables one to link candidate entrainers
curve and pinch point curve passing directly to flowsheets facilitating the desired
through the product composition. These separation between azeotrope-forming
regions form the basis of a feasibility test: If components a and b.
the bounds of the composition profiles do Singular points, which are pure
not intersect or overlap, the two proposed components and azeotropes, are labelled
products cannot be obtained in a according to the convention shown in Fig. 1.
single-feed column. This concept is an secondary
product 1. Primary product
extension of the one proposed by Levy et al. 1 2. Secondary product
3. Entrainer
(1985), who uses the intersection of liquid 0.8
2 4. Binary azeotrope to be
separated

composition profiles for the two proposed


5. Entrainer-secondary
product binary azeotrope
6. Entrainer-primary product
products as a criterion for feasibility.
0.6
binary azeotrope
5 7. Ternary azeotrope
This work presents a systematic method 0.4 7 4

for identifying promising entrainers for the


0.2
separation of binary azeotropic mixtures. 3 6
1
Promising entrainers are identified using a 0
0 0.2 0.4 0.6 0.8 1
primary
new classification of ternary mixtures which entrainer
product

is able to link candidate entrainers to Fig. 1: Convention for labelling singular


flowsheet structures. points in the standard distillation line map.

NEW CLASSIFICATION SYSTEM FOR The primary product is the first


TERNARY MIXTURES azeotropic constituent to be produced as a
pure component product in the flowsheet.
It is assumed that, in ternary mixtures, Which azeotropic constituent is selected to
only one binary azeotrope can be formed in be the primary product affects which
each binary system and only one ternary flowsheets will be feasible and the
azeotrope can be formed. Although performance of feasible flowsheets.
counter examples have been reported in the Therefore, part of the synthesis problem is
literature (Gaw and Swinton, 1966), these the selection of primary and secondary
cases are quite rare. These assumptions products.
restrict the number of potential residue This work assumes that the composition
curve maps or distillation line maps for a and temperature of all azeotropes at a given
ternary system to 125 (Doherty and Perkins, system pressure can be reliably calculated,
1979). and that the structure of the resulting
In this work, ternary mixtures are distillation line map can be characterised in
characterised using a ‘standard distillation a consistent fashion (stability of singular
line map’, which is a characterisation system points, origins and termini of boundaries,
24 Synthesis of Ternary Homogeneous Azeotropic Distillation Sequences: Entrainer Selection

etc). Distillation boundaries can be identification of which categories of


conveniently approximated using distillation standard distillation line maps to lead to
lines starting from the vicinity of saddle type feasible separations. Which flowsheets can
azeotropes. The distillation boundary always be used to facilitate the desired separation
connects saddle- and node-type singular can be derived directly from the
points and separates two distillation regions classification.
(Doherty and Perkins, 1979).
The standard distillation line maps is ENTRAINER SELECTION
defined in this work in terms of class (related
to the termini of distillation boundaries in The mixture to be separated into its pure
the composition space), and type (related to component products is assumed to be a
the stability of the products’ singular points). binary azeotropic mixture, but not
The standard distillation line map is necessarily the azeotrope itself. Two
classified using the general term: approaches to entrainer selection presented
i j k (l) – z Type p (q) in the literature form the basis for the new
where Table 1 defines the indices. The selection criteria. The first approach requires
classification system is applied to a number both products to be located in the same
of systems later in the paper. distillation region (Doherty and Caldarola,
All distillation line maps identified in 1985). In the second approach (Stichlmair
previous work (Stichlmair and Herguijuela, and Herguijuela, 1992), entrainers are
1992) can be classified using the new system. selected such that both products are termini
The new classification system allows

Table 1. Key to standard distillation line map classification – ijk (l) – z Type p (q)

Index Singular point Character Key


referred to
i 5 O Binary azeotrope does not exist
j 6 A Binary azeotrope is not terminus of distillation
k 4 boundary
X Binary azeotrope is terminus of distillation boundary
z 7 Y Ternary azeotrope is a terminus of distillation
boundary (blank otherwise)
l 1,2,3 1,2,3,12,13,23,12 List of all pure component singular points lying on
3 distillation boundaries (blank otherwise)
p 1,2 O Both products are nodes
A Primary product is saddle; secondary product is
node
B Primary product is node; secondary product is
saddle
C Both products are saddles
q 5,6 5,6,56 List all saddle-type binary azeotropes (blank
otherwise)
Sutijan, Megan Jobson, and Robin Smith 25

of distillation lines (i.e. nodes in the distillation boundary must be crossed or


distillation line map) and are separated by a relocated (‘shifted’). The feed of a
distillation boundary. When entrainers boundary-crossing column is located in one
introduce a ternary azeotrope, the distillation region, and both products are
azeotrope must be the same type (i.e. located in another adjacent distillation
maximum or minimum boiling) as the region (Laroche et al., 1992). Boundary
azeotrope of interest. In this work, both crossing requires the boundary to be curved.
approaches are adopted and extended to As the curvature of the boundary decreases,
accommodate other entrainers. the flow rates of recycled streams will
An entrainer which does not introduce a increase, by the lever arm rule, leading to
distillation boundary between the two economically unattractive flowsheets.
components to be separated is a promising Flowsheets employing boundary shifting
entrainer (Doherty and Caldarola, 1985). In (Knapp and Doherty, 1992) exploit the
this case, both products and the binary pressure-sensitivity of azeotrope
azeotropic feed are located within the same composition and the location and curvature
distillation region. The feed mixture can be of the boundary. At least two columns in
separated using recycle streams in the the flowsheet operate at different operating
distillation flowsheet (i.e. without boundary pressures; two different boundaries
shifting or crossing). All standard constrain the two columns. Both straight
distillation line maps satisfying the criteria of and curved boundaries can be shifted to
Doherty and Caldarola (1985) are listed in good effect. The introduction of new
Figs. 2 and 3. azeotropes in the mixture with a change in
Fig. 2 shows standard distillation line operating pressure has previously not been
maps in which one of the products is a accommodated. As will be shown, this
saddle and no boundary separates the phenomenon can even enhance the
desired products. The maps are ordered separation when the existing azeotropes are
according to the number of binary pressure-sensitive.
azeotropes present in the mixture. For Fig. 4 presents the standard distillation
simplicity, all distillation boundaries are line maps for entrainers that introduce a
drawn using straight lines. All standard boundary between the components to be
distillation line maps in which no boundary separated and which adhere to the entrainer
separates the desired products and where selection criteria of Stichlmair and
both products are saddles (type C) are Herguijuela (1992). These criteria stipulate
presented in Figure 3. that the ternary azeotrope must be of the
Many entrainers introduce a distillation same type (i.e. maximum or minimum
boundary between the two components to boiling) as the azeotrope of interest. In this
be separated. In this case, the two products work, this criterion is relaxed in the case that
are located in different distillation regions. both desired products are nodes in the
Separation cannot be achieved using only distillation line map. In the presence of a
distillation and recycle streams. In order to ternary azeotrope, the only requirement for
be able to recover the products, the an entrainer to be feasible is that both
26 Synthesis of Ternary Homogeneous Azeotropic Distillation Sequences: Entrainer Selection

OOX-Y type A OOX-Y type B AXX(2) - Y type A(6)

Classes*:
- 023 Classes*:
- 320 Classes*: - 323
- 104 - 323 - 114
- 014 - 114

XOA(1) type B(5) XAA(1) type B(5) AXA(2) type A(6)

Classes*:
Classes*: Classes*:
- 400-M
- 400-M - 124-m
- 200-m
- 200-m - 214-m
- 423-M
- 324-M

OOX-Y type A OOX-Y type B AXX(2) - Y type A(6)

Classes*: Classes*: Classes*:


- 124-m - 204-m - 204-m
- 214-m - 024-m - 024-m
- 423-M - 420-M - 420-M
- 324-M - 024-M - 024-M

XAX(1) - Y type B(5) OXX(2) - Y type A(6) XOX(1) - Y type B(5)

Classes*:
Classes*: - 214-m
- 214-m - 124-m
- 124-m - 423-M
- 423-M - 324-M
- 324-M

XXA(2) - Y type A(6) XXA(1) - Y type B(5)

Fig. 2: Standard distillation line maps corresponding to feasible entrainers for which the
two pure products are located in the same distillation region. One of the products is a
saddle. (*: Existing classification of Stichlmair and Herguijuela, 1992)
Sutijan, Megan Jobson, and Robin Smith 27

Classes*: Classes*:
- 030 - 301
- 001 - 130

OOA type C AOA type C

Classes*:
- 213
Classes*: - 312
- 031 - 132
- 130 - 431
- 134
- 314

OAA type C XXA type C(5)

Classes*:
- 123 Classes*:
- 321 - 040-M
- 231 - 002-m
- 341
- 143
- 413

XXA type C(6) OOX-Y type C

Classes*:
Classes*: - 041-M
- 041-M - 401-M
- 401-M - 032-m
- 032-m - 230-m
- 230-m

OAX-Y type C AOX-Y type C

Fig. 3: Standard distillation line maps for entrainers for which two pure
products are located within the same distillation region. Both products are
saddles. (*: Existing classification of Stichlmair and Herguijuela, 1992)

products are nodes and are connected by three-column flowsheets can be generated
distillation boundaries or so that all column specifications satisfy the
composition-space boundaries via a common saddle criterion, which indicates
saddle-type ternary or binary azeotrope. column feasibility (Rooks et al., 1998; Thong,
For these entrainers, two-column or 2000). An example of an entrainer of this
28 Synthesis of Ternary Homogeneous Azeotropic Distillation Sequences: Entrainer Selection

Classes*:
Classes*: - 120
- 020 - 201 Classes*:
- 004 - 430 - 102
- 304 - 012
- 043
- 340

OOX(3) type O OXX type O XOX type O(5)

Classes*:
Classes*:
Classes*: - 021
- 221
- 102 - 201
- 212
- 012 - 430
- 443
- 043 - 304
- 344
- 340

OXX type O(6) XOX type O XXX type O(5)

Classes*: Classes*:
- 221 - 122
- 122 - 212
- 434 - 221
- 344 - 443
- 434
- 344

XXX type O(6) XXX type O(56)

Classes*: Classes*: Classes*:


- 022-m - 022-m - 222-m
- 202-m - 202-m - 444-M
- 044-M - 044-M
- 440-M - 440-M

OXX-Y type O(6) XOX-Y type O(5) XXX-Y type O(56)

Fig. 4: Standard distillation line maps for promising entrainers where the two node-type
desired products are located in different distillation regions. (*:Existing classification of
Stichlmair and Herguijuela, 1992)

type and a feasible flowsheet not previously in one or both desired products being
identified as suitable, is shown in Fig. 5. Fig. saddles in the distillation line map. Using a
6 represents standard distillation line maps combination of a double-feed column and
for feasible entrainers where the ternary boundary shifting, or recycling and mixing,
azeotrope is not of the same type as the entrainers which introduce a distillation
binary azeotrope of interest. boundary between the two components to
The criteria of Stichlmair and Herguijuela be separated, one of which is a saddle, can
(1992) always reject entrainers which result still facilitate the desired separation. Such
Sutijan, Megan Jobson, and Robin Smith 29

B
1
B2 Binary azeotrope : unstable node
distillation boundary (minimum boiling azeotrope)
0.8 at P 1
Ternary azeotrope : saddle

0.6 C-2
azeotrope (P1)
azeotrope (P2)
0.4 D1 feed
distillation boundary
0.2 C-1 at P 2
D2
B1
0
0 0.2 0.4 0.6 0.8 1
E A

Fig. 5: Example of a distillation line map XOX(12) type O for an entrainer that introduces a
ternary azeotrope of a different type to the binary azeotrope of interest. A two-column
flowsheet with boundary shifting can facilitate the separation.

Classes*:
Classes*: Classes*: - 011-S
- 003-S - 110-S - 101-S
- 010-S - 101-S - 330-S
- 330-S - 033-S
- 033-S

OOX(123)-Y type O OXX(12)-Y type O XOX(12)-Y type O

Classes*:
Classes*: - 112-S
- 121-S - 211-S
- 211-S - 433-S
- 343-S - 334-S
- 433-S

XXX(12)-Y type O(6) XXX(12)-Y type O(5)

Fig. 6: Standard distillation line maps for promising entrainers in which the two node-type
desired products are located in different distillation regions. The entrainer introduces a
ternary azeotrope of a different type (i.e. maximum, intermediate or minimum boiling) to the
azeotrope of interest. (*: Existing classification of Stichlmair and Herguijuela, 1992)

Classes*: Classes*:
- 201 - 021
- 120 - 120
- 403 - 034
- 043 - 304

XOX type A(5) OXX type B(6)


Fig. 7: Standard distillation line maps for promising entrainers for which the two desired
products are located in different distillation regions and one of which is a saddle. (*: Existing
classification of Stichlmair and Herguijuela, 1992)
30 Synthesis of Ternary Homogeneous Azeotropic Distillation Sequences: Entrainer Selection

Fig. 8: Distillation line maps of entrainers considered for the separation of an


acetone-chloroform mixture. Acetone is the primary product. (√ : promising, × : not
promising)

entrainers violate the criteria of both distillation is not a cost-effective design


Doherty and Caldarola (1985) and Stichlmair option. An entrainer is needed to facilitate
and Herguijuela (1992). Standard the separation. Since the binary feed is
distillation line maps for this type of richer in acetone than chloroform, acetone is
candidate entrainer are presented in Fig. 7. selected as the primary product. The
Identification of feasible flowsheets for composition, temperature and stability of
given standard distillation line maps will be singular points and existence and termini of
presented in a further work. distillation boundaries are calculated at
atmospheric pressure using the methods of
CASE STUDY Fidkowski et al. (1993). The distillation line
maps is classified based on the stability of
This example addresses the separation of singular points and the existence and
a mixture of acetone and chloroform, in termini of distillation boundaries. Suitable
which components form a maximum-boiling flowsheets for each entrainer are identified
azeotrope. Promising entrainers and the directly, given the standard distillation line
associated flowsheets are selected map classification (from Figures 2 to 7).
according to the new methodology. Figure 8 and Tables 2 present the eight
The binary feed mixture, which contains entrainers to be considered. The physical
60 mole % acetone and 40 mole % properties of the pure compounds are
chloroform, is to be purified using obtained from Reid et al. (1987) and
homogeneous azeotropic distillation. vapour-liquid equilibrium behaviour is
Acetone and chloroform form a calculated using the Wilson model and the
maximum-boiling azeotrope. Since the default model parameters from Hysys. The
azeotrope composition is set of flowsheets that are suitable for each
pressure-insensitive, binary pressure-swing acceptable entrainer is obtained directly
Sutijan, Megan Jobson, and Robin Smith 31

Table 2. Some physical properties, distillation line map characteristics and corresponding
feasible flowsheets of candidate entrainers for the separation of an acetone-chloroform
mixture.
(BS: boundary shifting, BC: boundary crossing, RM: recycling and mixing, DF: double feed
column)

Primary Secondary Flowsheet


Entrainer Formula BP, °C Boundary Classification Accept?
product product Structures
Acetic acid C2H4O2 117.95 Exists OOX(3) type O Node Node Yes BS, RM
Acrylic acid C3H4O2 141 Exists OOX(3) type O Node Node Yes BS, RM
Benzene C6H6 80.09 Exists OOX(3) type O Node Node Yes BS, BC
F6 acetyl C3F6O 54.15 No OOA type C Saddle Saddle Yes DF
acetone
Methanol CH4O 64.65 Exists XX(3)-Y type C Saddle Saddle No None
Methyl ethyl C4H8O 79.55 Exists XOX type O Node Node Yes BS, BC
ketone
Thio acetic
BS, RM
acid C2H4OS 87.05 Exists OOX(3) type O Node Node Yes
Toluene C7H8 110.65 Exists OOX(3) type O Node Node Yes BS,BC

once the ternary mixtures have been advantage of the new characterisation
classified (see Table 2). Of the candidate system is that suitable flowsheets can be
entrainers, only methanol is not suitable: in identified immediately. A new set of
this case the two products would be both entrainer selection criteria is defined; it
saddles separated by a distillation boundary. expands significantly the set of previously
For this class of distillation line maps, there published criteria by accepting many
is no feasible flowsheet that can be candidate entrainers that violate existing
generated. Detailed discussion on feasible entrainer screening criteria.
flowsheet identification will be presented in This new classification system allows
a further work. promising entrainers to be identified easily
and potentially feasible flowsheets to be
CONCLUSIONS derived directly. The methodology is
therefore valuable and powerful for the
A new classification system for synthesis of ternary homogeneous
homogeneous ternary azeotropic mixtures azeotropic distillation processes.
has been developed for the purposes of
screening candidate entrainers for ACKNOWLEDGMENTS
separating a binary azeotropic mixture into
its pure component products. The The authors thank the Engineering
‘standard distillation line map’ is classified Education Development Project of Indonesia
according to the presence and termini of for their financial support of Dr Sutijan.
distillation boundaries and the type
(stability) of binary azeotropes and products. References
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32 Synthesis of Ternary Homogeneous Azeotropic Distillation Sequences: Entrainer Selection

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