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Article history: The industrial production of anhydrous bioethanol requires energy demanding distillation steps to over-
Received 17 June 2011 come the azeotropic behavior of the ethanol–water mixture. In spite of the recent developments in per-
Received in revised form 7 October 2011 vaporation and adsorption with molecular sieves, the large scale production is still dominated by
Accepted 18 October 2011
extractive and azeotropic distillation as the separation technology of choice.
Available online 25 October 2011
This study proposes novel distillation technologies for enhanced bioethanol dehydration, by extending
the use of dividing-wall columns (DWC) to energy efficient extractive distillation (ED) and azeotropic dis-
Keywords:
tillation (AD). Notably, DWC is one of the best examples of proven process intensification technology in
Dividing-wall column
Azeotropic
distillation, as it allows significantly lower investment and operating costs while also reducing the equip-
Extractive distillation ment and carbon footprint.
Ethanol dehydration For both ED and AD cases a classic sequence of two distillation columns and the alternative based on
Energy savings DWC are optimized using the state of the art sequential quadratic programming (SQP) method. A mixture
of 85 mol.% ethanol is dehydrated using ethylene glycol and n-pentane as mass separating agents in an
extractive and azeotropic distillation setup, respectively. The results of the rigorous simulations per-
formed in Aspen Plus show that energy savings of 10–20% are possible for the novel process intensifica-
tion alternatives based on DWC, while using less equipment units as compared to the conventional ED
and AD configurations.
Ó 2011 Elsevier B.V. All rights reserved.
1383-5866/$ - see front matter Ó 2011 Elsevier B.V. All rights reserved.
doi:10.1016/j.seppur.2011.10.022
A.A. Kiss, D.J-.P.C. Suszwalak / Separation and Purification Technology 86 (2012) 70–78 71
Extractive Distillation
A B
S
B,S
A,B
A B
B,S
A,B
Distillation
Extractive DWC
Azeotropic Distillation
azeotrope E-rich
phase
azeotrope
E-rich
A,B B-rich
phase
phase
B A A,B
B-rich
phase
B A
Distillation
Azeotropic DWC
However, they do reach their limits in case of large scale separa- An innovative solution to overcome the drawback of energy
tions [48,14]. Adsorption with molecular sieves became recently intensive distillation is using advanced process intensification
more popular as it requires less energy than distillation. However, and integration techniques, such as thermally coupled distillation
the desorption step requires high temperature and/or low pres- columns, dividing-wall columns, heat-integrated distillation col-
sure, thus leading to higher overall equipment costs [17,48,14]. umns, or cyclic distillation [19,8,45,20,34–36,15,2,10–12,31]. The
Distillation methods, such as ED and AD, present relatively high Petlyuk configuration consisting of two fully thermally coupled
energy costs but in spite of this major drawback, they are still the op- distillation columns [36] evolved to the practical implementation
tion of choice in case of large scale production of bioethanol fuel in a dividing-wall column (DWC) that splits the middle section of
[48,14]. Usually, ED and AD are performed in a conventional a single vessel into two sections by inserting a vertical wall in
sequence of two columns, first of them separating ethanol while the vessel, at an appropriate position [19,10,27]. DWC found great
the other splits water from the recovered mass separating agent appeal in the chemical process industry because it can separate
(MSA) that is recycled back. more components in a single distillation unit, thereby saving the
72 A.A. Kiss, D.J-.P.C. Suszwalak / Separation and Purification Technology 86 (2012) 70–78
Fig. 3. Residue curve map (left) and ternary diagram (right) of the mixture ethanol–water–glycol.
2. Problem statement
Ethanol Water
In order to be used as fuel or additive, bioethanol must have the
purity equal or higher than 99.0–99.8 wt.%, according to the inter-
Solvent national standards (EN 15376, ASTM D 4806). Most of the water
present in the diluted ethanol/water mixture (5–12 wt.%) from
DC1 DC2 the fermentation step is removed by simple distillation, but the
purity of the bioethanol product is limited to maximum
Feed
95.6 wt.% due to the presence of a binary azeotrope with water.
Cyclic distillation was recently described as an energy efficient
alternative for concentrating ethanol, but this method is also lim-
DC1 ited by the azeotropic composition [31]. The industrial processes
BTM Ethylene currently used to remove water from ethanol involve pervapora-
glycol
tion, adsorption, pressure-swing distillation, extractive and azeo-
Fig. 4. Aspen Plus flowsheet of the two-columns extractive distillation sequence.
tropic distillation, or a combination of these.
The problem of all these methods is either the high energy
requirements or the high equipment costs leading to penalties in
cost of building two columns and cutting the operating costs by the operating costs and long payback times. Considering the high
using a single condenser and reboiler. In fact, using DWC can save demand of bioethanol, new alternatives are needed to reduce these
up to 30% in the CapEx and up to 40% in OpEx [41,18]. Several costs. To solve this problem, we propose here two novel extractive
excellent reviews and research papers were published on this to- and azeotropic distillation alternatives based on DWC that allow
pic, covering the design, simulation, control, optimization and over 10% and 20% energy savings in case of E-DWC and A-DWC,
applications of DWC [47,51,44,40,49,42,37,2,11,13,25,26,39,52]. respectively. Remarkably, the energy requirements are reduced
Remarkable, the DWC technology is not limited to ternary separa- while using a lower number of equipment units as compared to
tions alone, but it can be used also in azeotropic separations the conventional ED and AD systems.
[32,46], extractive distillation [7], and even reactive distillation
[33,23,16]. 3. Results and discussion
Fig. 1 illustrates the path from a classic distillation column to an
extractive DWC, while Fig. 2 shows the development from a con- This section describes the results on the conventional and DWC
ventional system to an azeotropic DWC [52]. In this work, we alternatives for extractive and azeotropic distillation. Aspen Plus
investigate the application of these novel E-DWC and A-DWC simulations were performed using the rigorous RADFRAC unit with
configurations to the enhanced dehydration of bioethanol, from RateSep (rate-based) model, and explicitly considering three phase
85 mol.% (93.5 wt.% ethanol) to the required standard purity balances. NRTL and UNIQUAC property methods can be used due to
(>99.8 wt.%). This particular feed stream is obtained after a pre- the presence of a non-ideal mixture containing polar components.
concentration step by ordinary distillation that follows the produc- Both methods were successfully used in the past, practically lead-
tion of bioethanol in a fermentation reactor, which increases the ing to very similar results [5,28].
concentration from 5 to 93.5 wt.% ethanol. Ethylene glycol and Note that in the pre-concentration step, the diluted ethanol
n-pentane are used here as mass separating agents (MSA) in an stream (5 wt.%) obtained by fermentation is conveniently distilled
extractive and azeotropic distillation, respectively. Unlike other to the near-azeotropic composition of 93.5 wt.% ethanol. This is
studies comparing a non-optimal classic sequence with an typically performed by an ordinary distillation column that re-
optimized alternative, here we make a fair comparison between quires significant thermal efforts of up to 2.6 kW h/kg bioethanol,
an optimal conventional sequence and the optimized DWC alterna- due to the large amount of water that needs to be separated. How-
tive. Backed by a solid theoretical and computational foundation, ever, the pre-concentration step is out of the scope of this paper,
the sequential quadratic programming (SQP) method has arguably since this ordinary distillation is quite trivial [14]. The feed stream
become the most successful method for solving non-linearly con- considered here is the one obtained from the pre-concentration
strained optimization problems [6,4]. Our results clearly show that stage of bioethanol, and consists of a mixture of 85 kmol/h
significant energy savings of 10–20% are possible while using less (3915.9 kg/h) ethanol and 15 kmol/h (270.2 kg/h) water thus hav-
equipment units. ing a near azeotropic composition (93.5 wt.% ethanol). The target
A.A. Kiss, D.J-.P.C. Suszwalak / Separation and Purification Technology 86 (2012) 70–78 73
Table 1
Design parameters of an optimal two-column extractive distillation sequence.
Ethanol Water
Ethanol Water
Solvent Solvent
Prefrac DWC
Feed
Feed Vap1
Liq1
Fig. 6. Scheme of the proposed E-DWC (left). Thermodynamically equivalent, decomposed flowsheet of E-DWC suitable for simulation (right).
Table 2
Design parameters of the optimized E-DWC.
Table 3
Comparison condenser and reboiler duty for extractive distillation.
Fig. 7. Temperature and composition profiles in the E-DWC (dashed line used for Direct sequence ED E-DWC
the pre-fractionator side, while continuous line is used for the main DWC side).
DC1 DC2 Total PreFrac DWC Total
Condenser 1200.62 367.29 1567.90 1175.01 205.09 1380.10
ucts of the extractive dividing-wall column: ethanol and water as duty (kW)
Reboiler 1402.43 605.39 2007.82 0.00 1819.52 1819.52
top distillates, and EG solvent as recovered bottom product.
duty (kW)
It is important noting that for the optimal design a different
number of stages was obtained on both sides of the dividing-wall,
as they are actually manipulated variables and no restriction was
applied with regard to having the same number of stages on both 3.2. Azeotropic distillation
sides of the wall. Moreover, a dividing-wall with symmetry on both
side of the wall does not systematically represent the best scheme Azeotropic distillation is carried out by adding other chemicals
to achieve the required separation [7]. to generate a new, lower-boiling azeotrope that is heterogeneous –
Table 3 presents a comparison of the reboiler and condenser thus producing two, immiscible liquid phases. In some meanings,
duties for the conventional two-column sequence versus the pro- adding an entrainer is similar to extractive distillation. However,
posed E-DWC. The specific energy requirements are calculated at in case of extractive distillation, a high-boiling mass separating
0.51 kW h/kg for ED and 0.46 kW h/kg bioethanol for E-DWC, agent is used leading to lower energy demands as compared to
respectively. Energy savings of around 10% are possible with the azeotropic distillation, as the high-boiling solvent does not have
E-DWC, as compared to ED. These savings are lower than the to be evaporated [52].
usually reported values of 25–40%, due to the fact that the conven- One of the best entrainers for bioethanol dehydration by azeo-
tional ED sequence was also optimized in this study. tropic distillation is n-pentane, as it forms a low-boiling ternary
A.A. Kiss, D.J-.P.C. Suszwalak / Separation and Purification Technology 86 (2012) 70–78 75
Fig. 8. Residue curve map (left) and ternary diagram (right) of the mixture ethanol–water–pentane.
Dec-org
Top2
Top1
DC1 DC2
Feed
Dec-aqua
Ethanol Water
azeotrope with ethanol and water [14]. Note that cyclohexane was
also successfully used as an alternative ([46]). The mixture etha-
nol–water–pentane presents three binary azeotropes, one ternary
heterogeneous azeotrope, and a significant liquid phase split enve-
lope, as clearly illustrated by the residue curve map (RCM) and the
ternary diagram shown in Fig. 8.
Similar to the previous case, a conventional two-column
sequence (Fig. 9) was simulated and then optimized accordingly.
Bioethanol is separated as bottom product of the first column
(DC1), while the ternary azeotrope ethanol–water–pentane is col-
lected as top distillate that is afterward sent to a decanter. The
decanting step allows the split of the ternary azeotrope in two
liquid phases, following the LL equilibrium tie lines. The organic
phase, containing mostly pentane, is recycled back to the first
column (DC1). The aqueous phase is fed to a second distillation col-
umn (DC2), where high purity water is collected as bottom prod-
uct, while the top stream of DC2 is also recycled back to the first
distillation column (DC1).
Fig. 10 plots the temperature and composition profiles in the
two distillation columns, while Table 4 lists the optimal design
parameters. These results confirm that pentane is a feasible entrai-
ner allowing an excellent separation of ethanol–water. However,
the solvent flowrate is larger as compared to the previous extrac-
Fig. 10. Temperature and composition profiles in DC1 and DC2 (two-columns
tive distillation case, thus leading to larger equipment size in order azeotropic distillation sequence).
to satisfy the purity and recovery requirements. Moreover, the
solvent has to be completely evaporated in this case due to the The extension to the A-DWC model follows the same simulation
low-boiling azeotrope that is formed, thus making the AD alterna- and optimization procedure as for the previously described E-
tive less energy efficient than extractive distillation. DWC. Fig. 11 (left) shows a schematic representation of the pro-
76 A.A. Kiss, D.J-.P.C. Suszwalak / Separation and Purification Technology 86 (2012) 70–78
Table 4
Design parameters of an optimal two-column azeotropic distillation sequence.
Dec-aqua
Top1 Top1
Liq1
DWC
Vap1
Feed Feed
Dec-aqua Postfrac
Fig. 11. Schematics of the proposed A-DWC (left). Equivalent A-DWC flowsheet (right).
A.A. Kiss, D.J-.P.C. Suszwalak / Separation and Purification Technology 86 (2012) 70–78 77
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