Distillation has historically been the main method for separating mixtures in the chemical process industry. However, despite the flexibility and widespread use of distillation processes, they still remain extremely energy inefficient. Increased optimization and novel distillation concepts can deliver substantial benefits, not just in terms of significantly lower energy use, but also in reducing capital investment and improving eco-efficiency. While likely to remain the separation technology of choice for the next few decades, there is no doubt that distillation technologies need to make radical changes in order to meet the demands of the energy-conscious society.

Advanced Distillation Technologies: Design, Control and Applications gives a deep and broad insight into integrated separations using non-conventional arrangements, including both current and upcoming process intensification technologies.

It includes:

• Key concepts in distillation technology
• Principles of design, control, sizing and economics of distillation
• Dividing-wall column (DWC) – design, configurations, optimal operation and energy efficient and advanced control
• DWC applications in ternary separations, azeotropic, extractive and reactive distillation
• Heat integrated distillation column (HIDiC) – design, equipment and configurations
• Heat-pump assisted applications (MVR, TVR, AHP, CHRP, TAHP and others)
• Cyclic distillation technology – concepts, modeling approach, design and control issues
• Reactive distillation – fundamentals, equipment, applications, feasibility scheme
• Results of rigorous simulations in Mathworks Matlab & Simulink, Aspen Plus, Dynamics and Custom Modeler

Containing abundant examples and industrial case studies, this is a unique resource that tackles the most advanced distillation technologies – all the way from the conceptual design to practical implementation.

The author of Advanced Distillation Technologies, Dr. Ir. Anton A. Kiss, has been awarded the Hoogewerff Jongerenprijs 2013.

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

1.5 Relative Volatility 13

1.6 Bubble Point Calculations 14

1.7 Ternary Diagrams and Residue Curve Maps 16

1.8 Analysis of Distillation Columns 24

1.9 Concluding Remarks 34

References 35

2 Design, Control and Economics of Distillation 37

2.1 Introduction 37

2.2 Design Principles 38

2.3 Basics of Distillation Control 44

2.4 Economic Evaluation 55

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

3.4 Modeling of a DWC 83

3.5 DWC Equipment 87

3.6 Case Study: Separation of Aromatics 97

3.7 Concluding Remarks 103

References 107

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

4.5 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

4.8 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

5.5 Energy Efficient Control Strategies 171

5.6 Concluding Remarks 180

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

7.4 Absorption–Resorption Heat Pumps 234

7.5 Thermo-acoustic Heat Pump 236

7.6 Other Heat Pumps 240

7.7 Heat-Integrated Distillation Column 244

7.8 Technology Selection Scheme 245

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

8.5 Design and Construction Options 282

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

9.5 Modeling and Design of Cyclic Distillation 327

9.6 Control of Cyclic Distillation 335

9.7 Cyclic Distillation Case Studies 338

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

10.6 Case Study: Advanced Control of a Reactive Distillation Column 371

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

Dr. Ir. Anton A. Kiss has a PhD degree in chemical engineering and around 15 years of academic research and education experience, supported by 5 years of industrial research experience in the area of distillation and integrated chemical processes. Currently, he works as project leader and senior researcher in Separation Technology at AkzoNobel Research, Development & Innovation, Deventer, The Netherlands, acting as the key expert in distillation, reactive-separations, and other integrated processes. In his capacity as an award-winning researcher in separation technologies – particularly in distillation –  Dr Kiss has given many lectures at universities and conferences and has  carried out more than 100 research & industrial projects. He has also supervised numerous graduation projects, and has published several textbooks and more than 50 scientific articles in peer-reviewed journals.