Sequencing Separation Trains

CHEN 4460 – Process Synthesis,

Simulation and Optimization

Dr. Mario Richard Eden

Department of Chemical Engineering
Auburn University

Lecture No. 4 – Sequencing Separation Trains

September 11, 2012

Contains Material Developed by Dr. Daniel R. Lewin, Technion, Israel

Process Design/Retrofit Steps

Assess Primitive
Problem

Detailed Process Plant-wide

Synthesis - Development Controllability
Algorithmic of Base-case Assessment
Methods

PART II
Detailed Design,
Equipment sizing, Cap.
Cost Estimation,
Profitability Analysis,
Optimization
Algorithmic Methods
 Lecture 4 – Introduction
• Almost all chemical processes require the separation of
chemical species (components), to:
 Purify a reactor feed
 Recover unreacted species for recycle to a reactor
 Separate and purify the products from a reactor

• Frequently, the major investment and operating costs of a

process will be associated with separation equipment

• For a binary mixture, it may be possible to select a

separation method that can accomplish the separation task
in just one piece of equipment.

• More commonly, the feed mixture involves more than two

components, involving more complex separation systems.
 Lecture 4 – Objectives

 Be familiar with the more widely used

industrial separation methods and their
basis for separation.

 Understand the concept of the separation

factor and be able to select appropriate
separation methods for liquid mixtures.
 Example: Butenes Recovery
Species b.pt.(C) Tc (C) Pc, (MPa)
Propane A -42.1 97.7 4.17
1-Butene B -6.3 146.4 3.94
n-Butane C -0.5 152.0 3.73
trans-2-Butene D 0.9 155.4 4.12
cis-2-Butene E 3.7 161.4 4.02
n-Pentane F 36.1 196.3 3.31
 Example: Butenes Recovery

100-tray column
C3 & 1-Butene in
distillate

Propane and
1-Butene recovery
Pentane withdrawn
as bottoms n-C4 and 2-C4=s
cannot be
separated by
ordinary distillation
(=1.03), so 96%
furfural is added as
2-C4=s withdrawn as an extractive agent
distillate. Furfural is (  1.17).
recovered as bottoms n-C4 withdrawn as
and recycled to C-4 distillate.
 Separation is Energy Intensive
• Unlike the spontaneous mixing of chemical species, the
separation of a mixture of chemicals requires an
expenditure of some form of energy

• Separation of a feed mixture into streams of differing

chemical composition is achieved by forcing the different
species into different spatial locations, by one or a
combination of four common industrial techniques:
 The creation by heat transfer, shaft work, or pressure reduction
of a second phase that is immiscible with the feed phase (ESA –
energy separating agent)
 Introduction into the system of a second fluid phase (MSA –
mass separating agent). This must be subsequently removed.
 Addition of a solid phase upon which adsorption can occur
 Placement of a membrane barrier
 Common Separation Methods

Separation Phase of Separation Developed or Separation

Method the feed agent added phase principle
Equilibrium L and/or V Pressure V or L difference
reduction or
flash heat transfer
in volatility
Distillation L and/or V Heat transfer V or L difference
or shaft work
in volatility
Gas V Liquid L difference
absorbent
Absorption in volatility
Stripping L Vapor stripping V difference
agent
in volatility
Extractive L and/or V Liquid solvent V and L difference
and heat
Distillation transfer
in volatility
Azeotropic L and/or V Liquid V and L difference
entrainer and
Distillation heat transfer
in volatility
 Common Separation Methods

Separation Phase of Separation Developed Separation

Method the feed agent or added principle
phase
Liquid-liquid L Liquid Second Difference in
Extraction solvent liquid solubility

Crystalli- L Heat Solid Difference in

zation transfer solubility or
m.p.
Gas V Solid Solid difference in
adsorption adsorbent adsorbabililty

Liquid L Solid Solid difference in

adsorption adsorbent adsorbabililty

Membranes L or V Membrane Membrane difference in

permeability
and/or
solubility
 Common Separation Methods

Separation Phase of Separation Developed Separation

Method the feed agent or added principle
phase
Supercritical L or V Supercritical Supercritical Difference
extraction solvent fluid in solubility
Leaching S Liquid L Difference
solvent in solubility
Drying S and L Heat V Difference
transfer in volatility
 Separation Method Selection
• The development of a separation process requires the
selection of:
 Separation methods
 ESAs and/or MSAs
 Separation equipment
 Optimal arrangement or sequencing of the equipment
 Optimal operating temperature and pressure for the equipment

• Selection of separation method depends on feed condition:

• Vapor Partial condensation, distillation, absorption,
adsorption, gas permeation (membranes)
• Liquid Distillation, stripping, LL extraction, supercritical
extraction, crystallization, adsorption, and dialysis
or reverse osmosis (membranes)
• Solid If wet  drying, if dry  leaching
 Separation Method Selection
• The separation factor, SF, defines the degree of separation
achievable between two key components of the feed. This
factor, for separation of component 1 from component 2
between phases I & II, for a single stage of contacting, is:

C = composition variable,
C 1I / C 2I
SF  I, II = phases rich in (8.1)
C 1II / C 2II components 1 and 2.

• SF is generally limited by thermodynamic equilibrium. For

example, in the case of distillation, using mole fractions as the
composition variable and letting phase I be the vapor and phase
II be the liquid, the limiting value of SF is given in terms of
vapor-liquid equilibrium ratios (K-values) as:
y 1 / x 1 K1 P1 s
SF    1 , 2  s  for ideal L and V  (8.2), (8.3)
y2 / x2 K2 P2
 Separation Method Selection
• For vapor-liquid separation operations that use an MSA that
causes the formation of a non-ideal liquid solution (e.g.
extractive distillation):
1LP1 s
SF  1,2  (8.5)
2LP2s
• If the MSA is used to create two liquid phases, such as in liquid-
liquid extraction, the SF is referred to as the relative selectivity,
β , where:
1II / 2II
SF  1,2  (8.6)
1I / 2I

• In general, MSAs for extractive distillation and liquid-liquid

extraction are selected according to their ease of recovery for
recycle and to achieve relatively large values of SF.
 Equal Cost Separators

Liquid-Liquid Extraction
should NOT be used
when α for ordinary
distillation is greater
than 3.2

Extractive distillation
should NOT be used
when α for ordinary
distillation is
greater than 2

Ref: Souders (1964)

 Summary – Separation Trains

On completion of this part, you should:

 Be familiar with the more widely used industrial separation

methods and their basis for separation.

 Understand the concept of the separation factor and be

able to select appropriate separation methods for liquid
mixtures.
 Other Business
• Next Lecture – September 20
– Sequencing Ordinary Distillation Columns (SSLW p. 216-223)