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Abstract
Anhydrous ethanol can be obtained from a dilute aqueous solution of ethanol via extractive distillation with potassium acetate.
Two process flowsheets with salt recovery were proposed. In the first, dilute ethanol is directly fed to a salt extractive distillation
column and, after that, the salt is recovered in a multiple effect evaporator followed by a spray dryer. In the second, the concentrated
ethanol from conventional distillation is fed to a salt extractive distillation column. In this case, salt is recovered in a single spray
dryer. In both processes the recovered salt is recycled to be used in the extractive distillation column. Every component of each
process was rigorously modeled and its behavior was simulated for a wide range of operating conditions. A global simulation was
then carried out. The results show that the second process is more interesting in terms of energy consumption than the first.
Furthermore, it would be easier to implement changes on existing benzene extractive anhydrous ethanol plants to convert them to
more ecologically attractive concentrated ethanol feed processes.
# 2002 Elsevier Science B.V. All rights reserved.
Keywords: Anhydrous ethanol; Salt extractive distillation; Spray dryer; Multiple effect evaporators
1. Introduction
A highly used technique in industry to separate
azeotropic mixtures such as ethanol /water is extractive
distillation with liquid separation agents. There are
several liquid separation agents that can be used in
ethanol dehydration such as benzene, pentane, furfural,
ethylene glycol, diethyl ether and toluene. The most
utilized is benzene, which, due to its carcinogenic effect,
has been progressively eliminated.
One alternative process to produce anhydrous ethanol
is the extractive distillation that uses soluble salts as
separation agents. One comprehensive review of the
literature related to the vapor/liquid equilibrium of salt
systems and the salt extractive distillation was presented
by Furter and Cook [1] and complemented by Furter [2].
The salt extractive distillation is basically similar to
extractive distillation with liquid entrainers. The salt, a
non-volatile component, is introduced at the top or near
* Corresponding author
E-mail address: kakuta@desq.feq.unicamp.br (T.M.K. Ravagnani).
0255-2701/02/$ - see front matter # 2002 Elsevier Science B.V. All rights reserved.
PII: S 0 2 5 5 - 2 7 0 1 ( 0 2 ) 0 0 0 7 5 - 2
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E.L. Ligero, T.M.K. Ravagnani / Chemical Engineering and Processing 42 (2003) 543 /552
2. Proposed processes
The success of salt extractive distillation to produce
anhydrous ethanol is directly related to the salt chosen.
The choice of the correct salt for extractive distillation is
not exclusively limited to its ability to break the
azeotrope, but other factors including toxicity, easy
handling properties resulting from the system and
availability in the marketplace should also be taken
into account. The salt used in both processes was
potassium acetate. It is able to completely eliminate
ethanol /water azeotrope under atmospheric pressure
even if it is present in small concentrations in the liquid
phase of the extractive column [8,10].
In the anhydrous ethanol production by the salt
extractive distillation technique, the following two
distinct steps were taken into account: the production
step and the salt recovery step. In the first step, the
dilute ethanol aqueous solution was fed to a salt
distillation column in order to produce 98.9 mol%
anhydrous ethanol. Next, the dilute salt solution produced at the bottom of this column was fed to the
recovery step, where it was completely dried. Finally, the
recovered salt was reintroduced in the distillation
column within the reflux stream.
The proposed processes for anhydrous ethanol production were named according to the aqueous solution
concentration of ethanol fed in the salt distillation
column as follows: process with dilute ethanol feed
and process with concentrated ethanol feed.
E.L. Ligero, T.M.K. Ravagnani / Chemical Engineering and Processing 42 (2003) 543 /552
545
l e;i
N
salt
X
(1Ee;i )ve1;i
hs vse;s
Ve
V e1
ve;i
s1
0
(1)
546
E.L. Ligero, T.M.K. Ravagnani / Chemical Engineering and Processing 42 (2003) 543 /552
For the water/potassium acetate system, the equilibrium relationships follow the Duhring rule, i.e. the
boiling temperature of the solution is a linear function
of the boiling temperature of pure water, which is
calculated according to the Sander et al. [13] method.
3.3. Spray drying chamber
The design of the spray dryer used in the final drying
process of potassium acetate follows the Gauvin and
Katta model [15]. This model joins the fundamental
principles of the transport phenomena with experimental evidences. Its major considerations are the assumption of a saturated condition of the drop surface and
neglect the falling-rate drying period, resulting in a
constant temperature on the surface of the particles. As
a quasi-one-dimensional condition, this model does not
take into account the temperature and the humidity
gradients of the drying air in the radial direction, in a
way that these variables remain uniform in a given
cross-section of the chamber. One major criterion of the
spray dryer design is that the largest particle formed at
the atomizer should be dried before it reaches the drying
chamber wall. The drying chamber is made up of an
upper cylindrical section in which the height and the
radius have the same length, and a lower conical section
in which the height is the same value of the cylindrical
part diameter. Another important aspect of the chamber
is the fact that the drying air is tangentially introduced
by a single flow into the top of the cylindrical section,
resulting in a co-current flow.
The chosen atomizer was a centrifugal pressure
nozzle, especially adequate for viscous solutions. The
atomizer characteristics and the droplet particle size
distribution are those presented by Gauvin and Katta
[15], except that the range of droplet diameter was 80/
350 mm.
In the model for the spray dryer, the equations of the
three-dimensional movement of the droplets in the
centrifugal and gravitational fields were solved simultaneously with the equat ions of mass and heat transfer
with a three-dimensional model of the airflow and with
the instantaneous properties of the drying air. The
following considerations were made:
4. Results
The following results correspond to process simulations of an anhydrous ethanol unit producing 13.5 mol/
s.
4.1. Dilute ethanol feed process
4.1.1. Salt distillation column
In this process, the dilute aqueous ethanol solution is
directly introduced into the column of salt distillation in
which the anhydrous ethanol is obtained as a distillate
[21]. The operating conditions of the atmospheric
pressure column are presented in Table 1. The table
also presents the operating conditions of the salt
distillation column used in the concentrated ethanol
feed process.
The potassium acetate, introduced in the salt distillation column, has its maximum flow determined as a
function of the molar fraction of the salt inside the
column. It should meet three requirements: salt solubi-
Table 1
Operating conditions of salt distillation column
Process type
Concentrated ethanol
feed
22.22
60
353.45
E.L. Ligero, T.M.K. Ravagnani / Chemical Engineering and Processing 42 (2003) 543 /552
547
Table 2
Design of salt distillation column
Process type
Number of stages
37
Optimum reflux ratio 2.5
Feed stage number
18
Salt flow (mol/s)
3.74
Reboiler duty (W)
4.85 106
35
1.2
5
1.80
3.07 105
Final solution
Components: water/KAc
Flow: 10.13 kg/s
Composition: 3.6 wt.% of salt
Temperature: 373.45 K
Components: water/KAc
Composition: 60 wt.% of salt
Steam pressure, 10.1 105 Pa; last effect pressure, 0.11 105 Pa.
548
E.L. Ligero, T.M.K. Ravagnani / Chemical Engineering and Processing 42 (2003) 543 /552
with six or more effects, the heat transfer area practically remains constant.
The relation between steam consumption and the
number of effects of the evaporation system follow the
pattern shown in Fig. 5. The increase from one to two
effects causes a strong reduction in the vapor consumption, and the use of an evaporator with five or more
effects causes the required amount of vapor to reach a
constant value.
Considering the relation between the heat transfer
area and the steam consumption with number of effects,
the simulation results show that the evaporation of
potassium acetate solution in a system with four effects
is the best option. The major variable values obtained in
the design of the evaporation system are presented in
Table 4.
One of the determining factors in the design of the
evaporation system is the final concentration of the
KAc. The results of the different final values of the
required solution concentration in the design of the
evaporation system are listed in Figs. 6 and 7. In the
analyzed concentration range, the heat exchange area is
more strongly affected by the final concentration of the
salt than by the total steam required to achieve
evaporation or by the pressure of the last effect.
4
76 m2
3.36 kg/s
2.16 107 W
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549
Table 5
Operating conditions of spray dryer
Feed
Process type
Flow (kg/s)
Salt composition (wt.%)
Temperature (K)
0.608
60
335.6
0.36
0.33
52.8
388.6
0.18
Feed solutions, water/potassium acetate; product, potassium acetate. Drying air: inlet moisture: 0.005 kg water/kg dry air; inlet temperature,
650.15 K; outlet temperature, 420.15 K.
Fig. 8. Effect of feed salt concentrations on dryer height and air flow
rate.
The feed for this column has the same flow, composition and temperature specifications shown in Table 1.
The purity level of the distillate concentration, however,
is limited by the composition of the ethanol /water
azeotrope. In order to prevent the use of a large number
of stages in the following salt distillation column, the
ethanol content in the distillate was set to 60 mol% and
its flow was kept at 22.22 mol/s.
The minimum reflux ratio and some combinations of
reflux ratio and number of stages that lead to the
production of a distillate with the desired specifications
are shown in Fig. 3. The results of the pre-concentrating
column operating in the optimum reflux of 1.1 are
presented in Table 7.
Table 6
Design of spray dryer
Dimension
Drying air flow (kg/s)
Total heat involved (W)
Process type
Radius (m)
Total height (m)
2.2
6.6
1.81
4.53 105
2.6
7.8
0.0156
5.55 105
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E.L. Ligero, T.M.K. Ravagnani / Chemical Engineering and Processing 42 (2003) 543 /552
Table 7
Design of pre-concentrating distillation column
Number of stages
Reflux ratio
Feed stage number
Reboiler duty
22
1.1
17
4.84 106 W
Table 8
Optimum reflux ratio of salt distillation column
Number of stages
Reflux ratio
T (bottom) (K)
35
40
45
1.2
1.1
1.1
1.80
1.65
1.65
0.170
0.158
0.158
388.5
387.3
388.0
E.L. Ligero, T.M.K. Ravagnani / Chemical Engineering and Processing 42 (2003) 543 /552
551
Table 9
Comparative energy consumption of processes
Distillation process (extractive/azeotropic)
Potassium acetate (concentrated
ethanol feed)
Ethylene glycol
Pentane
Benzene
Diethyl ether
5. Conclusion
The use of potassium acetate as an extractive agent in
the production of anhydrous ethanol has proven to be
an effective alternative in replacing highly toxic separation liquid agents, such as benzene.
Regarding the two possibilities of anhydrous ethanol
production studied, the simulation results showed that
the concentrated ethanol feed process is the most
advantageous alternative. Although this process needs
two distillation columns, it eliminates the need for a
multiple effect evaporator in the salt recovery step.
Compared with dilute ethanol feed process, it requires
lower reflux ratio, which means lower column diameter
and lower salt consumption. Furthermore, it would be
easier to implement changes on existing benzene extractive anhydrous ethanol plants to convert them to
more ecologically attractive concentrated ethanol feed
processes.
Appendix A: Nomenclature
CD
E
FL
/
/K
l
/
/L
N
Nsalt
Nsolv
N
V/
v
vs
T
hs
/ /
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552
i
s
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