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1
Separation processes II
Contents
Object
Introduction
Process Operations
Applicability
Theory
Limitations
Co-current model
Modeling
Conclusions
References
Appendix A
Appendix B
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Separation processes II
Object
Part A : Filtration
Filtration and drying are two important unit operations in most pharmaceutical
and chemical processes and are usually carried out in series. In the aspirin
production process you will have conducted mass and energy balances over the
filter. Based on these balances, critically examine a number of filtration options
and select what you consider to be the most suitable types, giving your reasons.
Filtration unit operation:
The stream from the crystalliser is fed to a filtration unit (feed composition is
based on the mass balance performed in Module 9001). Laboratory tests have
given the following data. (Assume an incompressible filter-cake and that the
resistance related to the filter medium and initial layer is negligible)
The filter cake porosity = 0.1
Filtrate specific gravity = 1.0 kg per litre
Specific resistance of the filter-cake, r = 8.0 x 1013 m-2.
Filtrate viscosity, μ = 1.0 x 10-3 Ns m-2
Design vacuum and pressure filtration units for the required duty. Support your
argument with clear references to both authoritative literature and your design
calculations.
After washing, the filter-cake is pre-dried down to 2.0%w/w water in the
filtration unit before being fed to the dryer.
Part C : Adsorption
Problem No. 1:
Adsorption on 6x10-mesh activated carbon is being considered to recover
methyl ethyl ketone (MEK) from an air stream at 25 oC and 1 atm. The airflow is
12,000 std ft3/min, and the air has 0.4 lb MEK/1000 std ft 3. If the superficial
velocity is 0.5ft/s, and an adsorption cycle of at least 8 h is desired, what bed
dimensions should be used? Assume the bulk density of the carbon is 30 lb/ft3.
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Separation processes II
Problem No. 2:
Granular carbon is used to remove phenol from an aqueous waste. If 10x20 –
mesh carbon is used with a superficial velocity of 0.03m/s, estimate the number
of transfer units in a bed 4 m deep. The effective diffusivity in the particles can
be taken as 0.2 times the bulk diffusivity.
T oC 14 25 41.6 79.6
P mm Hg 60 100 200 760
ρ = 0.805 g/cm3 at 20 oC
M= 72.1
Incoming air has 0.40 lb MEK/1000 SCF
0.40 / 72 .1
y= = 1.99*10 -3
mol fraction MEK
1000 / 359
p = 1.99*10-3 (760) =1.51 mm Hg
At 25 oC
(T/V) log (f/fs) = (298/98.7)log(100/1.51)= 5.498
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Separation processes II
At 40oC,
(T/V) log (f/fs) = (313/98.7)log(192.1/1.51)= 6.670
Lmin= 33/30=1.1 ft
If half the bed capacity is used at the breakpoint,a bed 2.2 ft long would suffice.
Then a racterngular bed 2-3 ft deep could be placed in the middle of a horizontal
cylinder vessel. This would be less expensive than a 23.6 ft diameter cylindrical
bed.
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Separation processes II
Introduction
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Separation processes II
also carried out in stagewise equipment, the prime example being a mixer–
settler unit in which the main features are the mixing of the two liquid phases by
agitation, followed by settling in a separate vessel by gravity.[1],[8]
EXTRACT
FEED
SOLVENT
RAFFINATE
A general extraction column has two input stream and two output streams. The
input streams consist of a solution feed at the top containing the solute to be
extracted and a solvent feed at the bottom which extracts the solute from the
solution. The solvent containing the extracted solute leaves the top of the
column and is referred to as the extract stream. The solution exits the bottom of
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Separation processes II
the column containing only small amounts of solute and is known as the
raffinate. Further separation of the output streams may be required through
other separation processes. In this case be practical distillation column for
further purification of ethanal, from the water – ethanal raffinate solution.
Therefore extraction is in many ways complementary to distillation and is
preferable in the following cases: [1],[8]
(a) Where distillation would require excessive amounts of heat, i.e. when the
relative volatility is near unity.
(b) When the formation of azeotropes limits the degree of separation obtainable
in distillation.
(c) When heating must be avoided.
(d) When the components to be separated are quite different in nature
Process Operation
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Separation processes II
kgEthannal 50
x2 = = = 0.0526 .
kgToluene 950
Applicability
It must decide which extractor would be relevant for our situation. The
specifications for each of these different systems are relatively the same. The
design limitations should be placed on each system in order to optimize the
individual process, maximize surface area of mass transfer, and adjust flow
feeds for maximum solute recovery. Generally, there are three main types of
extractors:
1. Mixer-settlers - are used when there will only be one equilibrium stage in the
process. For such a system, the two liquid phases are added and mixed. Due to
their density differences, one phase will settle out and the mixture will be
separated. The downfall to this type of extractor is that it requires a large-
volume vessel and a high liquid demand.
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Separation processes II
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Separation processes II
3. Centrifugal contractors - are ideal for systems in which the density difference
is less than 4%. In addition, this type of system should be utilized if process
requires many equilibrium stages. In these systems, mechanical devices are
used to agitate the mixture to increase the interfacial area and decrease mass
transfer resistance.
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Separation processes II
Bellow tabulated advantages and disadvantages for the various extractor types.
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Theory
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Separation processes II
The mixture in Figure 3 will separate into two phases following the tie line that
runs through point M. Point A is the raffinate phase and B is the extract phase.
Several other tie lines are shown. Point P represents the point where the two
phases are the same, this is known as the Plait point. The area of the two-phase
region and the path of the tie lines depend on the equilibrium data for the
system. These graphs change due to variables such as the components used in
the system, temperature, and pressure.
Equilibrium data
The equilibrium condition for the distribution of one solute between two liquid
phases is conveniently considered in terms of the distribution law. Thus, at
equilibrium, the ratio of the concentrations of the solute in the two phases is
given by CE/CR = K’ where K’ is the distribution constant. This relation will apply
accurately only if both solvents are immiscible, and if there is no association or
dissociation of the solute. If the solute forms molecules of different molecular
weights, then the distribution law holds for each molecular species. Where the
concentrations are small, the distribution law usually holds provided no chemical
reaction occurs. The addition of a new solvent to a binary mixture of a solute in
a solvent may lead to the formation of several types of mixture:
1. A homogeneous solution may be formed and the selected solvent is then
unsuitable.
2. The solvent may be completely immiscible with the initial solvent.
3. The solvent may be partially miscible with the original solvent resulting in the
formation of one pair of partially miscible liquids.
4. The new solvent may lead to the formation of two or three partially miscible
liquids. [1]
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Separation processes II
For the purpose of this exercise I assume that toluene and water are immiscible
and the distribution coefficient or K-value is 2.20 i.e. y = 2.2x, where y = kg
ethanal/kg water and x = kg ethanal/kg toluene.
W Y in
F X A , in F X A, out
EXTRACTION COLUMN
W Yout
Limitations
1. Suitable Solvent [4]
- Solvent partially soluble with the carrier.
- Feed components immiscible with the solvent.
- Solute is soluble in the carrier and at the same time completely or partially
soluble in the solvent.
- Different densities than the feed components for a phase separation to
facilitate and maintain the capacity of the extractor high.
- Extremely high selectivity for the solute for the solvent to dissolve the
maximum amount of solute and the minimum amount of the carrier.
- Large distribution coefficient to reduce the theoretical number of stages
contributing to a greater efficiency
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Separation processes II
- Low viscosity increases the capacity of the extraction column and does not
allow for the settling rate of dispersion to be slow.
- Chemically stable and inert toward other components of the system
- Low cost, non-toxic, and non-flammable.
2. Equipment
- Interfacial tension and Viscosity
- High interfacial tension and viscosity leads to more power being supplied to
maintain rapid mass transfer throughout the extraction process.
- Low interfacial tension and viscosity leads to the formation of an emulsion.
5. Separation may only occur for compositions in the region between the feed
composition and that apex of the carrier.
To find the minimum flow rate the slope from the equation need to be
calculated:
( y 2 − y1) (0.115 − 0)
SLOPE = = = 2.42
( x 2 − x1) (0.0526 − 0.005 )
2.42
a
=
s
Where a = 950 kg, therefore minimum flow rate:
950
S min = = 393 kg / hr
2.42
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Separation processes II
393 kg/hr is the minimum flow rate of water to achieve required purity of
toluene. Though to design extractor operating with this flow rate, will required a
large number of stages. The equilibrium curve is draw based on the equation
given as y = 2.2x .
0.12
0.1
kg ethanal/ kg water
0.08
0.06
0.04
0.02
0
0 0.01 0.02 0.03 0.04 0.05 0.06
kg ethanal/kg toluene
To choose proper operating conditions, a few different water flow rates will be
examine, and the results ware plotted. First step in this operation is to
determine the slope for each of the vary water flow rates.
For 400 kg/hr water flow rate slope will be:
950
Slope = = 2.38
400
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Separation processes II
( y 2 − y1)
SLOPE = where, x1= 0.005, x2= 0.0526, y1= 0, we can determine
( x 2 − x1)
unknown y2.
( y 2 − 0)
2.38 =
(0.0526 − 0.005 )
y2= 0.113
Tabulated data for different water flow rates for counter current model.
Flow rate Flow rate
water [kg] A [kg] Slope XN XF y1 y2
400 950 2.38 0.005 0.0526 0 0.113
600 950 1.58 0.005 0.0526 0 0.075
800 950 1.19 0.005 0.0526 0 0.057
1000 950 0.95 0.005 0.0526 0 0.045
1200 950 0.79 0.005 0.0526 0 0.038
1400 950 0.68 0.005 0.0526 0 0.032
1600 950 0.59 0.005 0.0526 0 0.028
1800 950 0.53 0.005 0.0526 0 0.025
2000 950 0.48 0.005 0.0526 0 0.023
Table 2: Results for vary water flow rate for counter current model.
The plot was created using Excel spreadsheet, as seen on next page on figure 9.
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Separation processes II
0.1
kg ethanal/ kg water
0.08
0.06
0.04
0.02
0
0 0.01 0.02 0.03 0.04 0.05 0.06
kg ethanal/kg toluene
equlibrium 0.0526 0.005 400 kg/hr water
600 kg/hr water 800 kg/hr water 1000 kg/hr water 1200 kg/hr water
1400 kg/hr water 1600 kg/hr water 1800 kg/hr water 2000 kg/hr water
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Separation processes II
Step 2: Calculate the number of stages. From graphic method steping off on the
plot from operating line to equilibrium line. This procedure should be repeated
until stages have been constructed to x1, the raffinate composition.
0.08 8
9
10
0.06 11
12
13
0.04
14
15
0.02
16
17
0 18
0 0.01 0.02 0.03 0.04 0.05 0.06
kg ethanal/kg toluene
Figure 10: Graphical method for determining the number of stages for the
counter current flow with water flow at 400kg/hr.
As can be seen for the flow water flow rate 400 kg/hr, which is close to amount
of minimum solvent = 393, the number of stages is 18.
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Separation processes II
Figure 11: Graphical method for determining the number of stages for the counter current flow with water flow at
600kg/hr,1000 kg/hr, 2000 kg/hr.
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Separation processes II
From the plot on the previous page, it is obvious by increasing amount of our
wash solvent decrees number of stages necessary to approach required purity of
our raffinate – toluene in this case. Tabulated results for vary water flow rate vs
number of stages.
20
18
16
number of stages
14
12
number of stages versu water
10
flow
8
6
4
2
0
0 500 1000 1500 2000 2500
Water flow [kg/hr]
Table 12: Plot number of stages versus water flow for counter current model.
Co-current model
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Separation processes II
For the co-current flow if the distribution law is followed, then the equilibrium
curve becomes a straight line given by y = mx. The material balance on the
solute may then be rewritten as:
Ax2 = Ax1 + Sy1 = Ax1 + Smx1 = (A + Sm)x1
and the number of stages is given by:
n = (log(x1/x2))/log[A/(A + Sm)]
unknown y1.
Tabulated data for different water flow rates for co-current model.
Flow
rate Flow
water raet A
[kg] [kg] Slope Xn Xf Slope y1 y2
400 950 2.38 0.005 0.0526 -2.38 0.113 0
600 950 1.58 0.005 0.0526 -1.58 0.075 0
800 950 1.19 0.005 0.0526 -1.19 0.057 0
1000 950 0.95 0.005 0.0526 -0.95 0.045 0
1200 950 0.79 0.005 0.0526 -0.79 0.038 0
1400 950 0.68 0.005 0.0526 -0.68 0.032 0
1600 950 0.59 0.005 0.0526 -0.59 0.028 0
1800 950 0.53 0.005 0.0526 -0.53 0.025 0
2000 950 0.48 0.005 0.0526 -0.48 0.023 0
Table 4: Results for vary water flow rates for co-current model.
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Separation processes II
0.1
kg ethanal/ kg water
0.08
0.06
0.04
0.02
0
0 0.01 0.02 0.03 0.04 0.05 0.06
equlibrium 0.0526 kg ethanal/kg
0.005 toluene 400 kg/hr water
600 kg/hr water 800 kg/hr water 1000 kg/hr water 1200 kg/hr water
1400 kg/hr water 1600 kg/hr water 1800 kg/hr water 2000 kg/hr water
Figure 13: Operating lines for vary water flow rates for co-current model.
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Separation processes II
The number of stages can be determined from graphic method, by stepping off
on the plot prom operating line to equilibrium line. This procedure should be
repeated until stages have been constructed to x1, the raffinate composition.
0.12
0.1
kg ethanal/ kg water
0.08
1
0.06
0.04 2
3
0.02 4
6 55
0
0 0.01 0.02 0.03 0.04 0.05 0.06
kg ethanal/kg toluene
equlibrium 0.0526 0.005 400 kg/hr water
600 kg/hr water 1000 kg/hr water 1400 kg/hr water 2000 kg/hr water
Figure 14: Graphical method for determining the number of stages for the
co-current flow with water flow at 400kg/hr.
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Separation processes II
Figure 15: Graphical method for determining the number of stages for the co-current flow with water flow at 600kg/hr,
1000kg/hr, 1400kg/hr, 2000kg/hr.
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Separation processes II
As can be observed from the plot on the previous page, the number of stages
for different water flow rates, changes as in the table bellow.
Table 5: Tabulated data for graphic method for estimation of number of stages
in co-current model
5
number of stages
4
number of stages vs water flow
rate for co-current model
3
0
0 500 1000 1500 2000 2500
Water flow[kg/hr]
Table 16: Plot number of stages versus water flow for co - current model.
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Separation processes II
After completing all estimation calculations, and choosing the best operating
conditions, the extraction column diameter, and height, can be determined as
well as the estimation operating cost. As shown in next few steps.
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Separation processes II
The total cost of the extraction is directly related to the extraction design
variables and type of extraction equipment applied. The variables that affecting
the economic balance are:
- at fixed solvent feed ratio, the amount of solvent extracted increases with
increased number of trays. Hence, the value of the unextracted solute may be
balanced against the cost of the extraction equipment required to recover it.
- for a fixed extent of reaction, the number of stages required decreases as the
solvent rate or reflux ratio increases. The capacity of the equipment necessary
for handling the larger liquid flow must increase with the larger reflux rate.
Hence, the cost of the equipment passes through a minimum when the
minimum numbers of stages are utilized.
- when reflux ratio and solvent rates are increased the extract solutions become
more dilute. Therefore, the cost of solvent removal is increased as well as the
operating cost for increased utilities.
As a result of these economic balances the total investment and operating costs
must achieved a minimum at the optimum solvent reflux rate. Additional cost
must be considered for the recovery of the saturated raffinate product as well as
the extract.
MODELING
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Separation processes II
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Separation processes II
1. ASPEN MODELS
A few of the choices are described here. The key decision must be make is what
model to use for the liquid phase activity coefficient. The Help/Physical Property
Methods/Choosing a Property Method menu gives advice about which
thermodynamic model is recommended for different applications. In the liquid
phase, the simplest option is an ideal liquid, with an activity coefficient equal to
1.0. That choice leads to Raoult’s law, which may suffice for similar chemicals.
Other models include regular solution theory using solubility parameters
(although not in Aspen Plus), NRTL, Electrolyte NRTL, UNIFAC, UNIQUAC, Van
Laar, and Wilson. Characteristics of the models are:[6]
1. The Electrolyte NRTL is especially suited for acid gas adsorption, which
includes the removal of carbon dioxide and hydrogen sulfide from a gas stream.
Refineries routinely use this process when making hydrogen. This is also one
way of capturing carbon dioxide from a power plant to capture and sequester it.
2. The UNIFAC model is a group contribution method that allows the model
parameters to be estimated using the molecular structure of each chemical.
When experimental data is not available, this is the only method that can be
used.
3. The UNIQUAC model uses binary parameters, which must be determined from
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Separation processes II
experimental data. Once found, however, the same parameters can be used in
multicomponent mixtures of three or more chemicals.
4. Both UNIFAC and UNIQUAC can be used when two liquid phases or
azeotropes are present.
5. The Van Laar options are less recommended in Aspen Plus; they are simpler
to use than the others, but less successful in general. In Aspen Plus the ease of
use is immaterial since someone else has created the program.
6. The Wilson equation is an option if there is only one liquid phase, and it does
handle azeotropes.
The simulations ware run based on two models, as they ware the most
applicable for the system of interest: UNIFAC and UNIQUAC.
32
Separation processes II
Overall flowsheet for extraction counter current mode in ASPEN , as seen bellow.
B1
6 8
Where:
Stream 6 – Water
Stream 7 - Feed
Stream 8 - Extract
Stream 9 - Raffinate
The run of the sensitivity simulation was based on vary water flow rate, which
was applied for a different number of stages in column. The comparison of
results obtained using different models types, based on information provide by
ASPEN Help Library Tool. Column was set-up in two modes: UNIFAC and
UNIQUAC, temperature = 15oC (ambient), pressure = 1 Atm (ambient).
On the next page tabulated data.
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Separation processes II
3 STAGES
1780 949.2092 44.13655 5.863455 1780 949.1978 47.58292 2.417084
1880 949.1715 44.61274 5.38726 1880 949.1603 47.88706 2.112941
1980 949.1337 45.03417 4.96583 1980 949.1233 48.1437 1.856299
2000 949.1261 45.11266 4.887341 2000 949.116 48.19015 1.809848
Table 6: Tabulated data for ASPEN simulation n-stages – vary water flow rate, table 1.UNIFAC mode.
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Separation processes II
5 STAGES
1780 949.1934 48.98069 1.019305 1780 949.1929 48.98037 1.019629
1880 949.1565 49.15472 0.84528 1880 949.1564 49.15465 0.845346
1980 949.1192 49.2935 0.706496 1980 949.1194 49.29358 0.706417
2000 949.1119 49.31784 0.682159 2000 949.1119 49.31784 0.682162
Table 7: Tabulated data for ASPEN simulation n-stages – vary water flow rate, table 2.UNIFAC mode.
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Separation processes II
1870
1670
1470
2 stages
Water [kg/hr]
1270 3 stages
4 stages
5 stages
1070
870
670
470
949.1 949.2 949.3 949.4 949.5 949.6 949.7 949.8
T olu ene [kg /hr]
Figure 18: Plot for results toluene Vs water for UNIFAC mode.
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Separation processes II
Bellow collected data for toluene versus ethanal in extract stream for 2, 3, 4,
and 5 stages in UNIFAC mode.
ETH1
45.0
40.0
KG/HR
35.0
30.0
25.0
949.05 949.1 949.15 949.2 949.25 949.3 949.35 949.4 949.45 949.5 949.55 949.6 949.65 949.7 949.75 949.8
TOLUEN KG/HR
Figure 19: Toluene Vs Ethanal in extract stream for 2 stages, UNIFAC mode.
ETH1
45.0
40.0
KG/HR
35.0
30.0
25.0
949.05 949.1 949.15 949.2 949.25 949.3 949.35 949.4 949.45 949.5 949.55 949.6 949.65 949.7 949.75 949.8
TOLUEN KG/HR
Figure 20: Toluene Vs Ethanal in extract stream for 3 stages, UNIFAC mode.
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Separation processes II
ETH1
45.0
40.0
KG/HR
35.030.0
25.0
949.05 949.1 949.15 949.2 949.25 949.3 949.35 949.4 949.45 949.5 949.55 949.6 949.65 949.7 949.75 949.8
TOLUEN KG/HR
Figure 21: Toluene Vs Ethanal in extract stream for 4 stages, UNIFAC mode.
TOLUEN
949.7
949.6
949.5
KG/HR
949.4949.3
949.2
949.1
22.0 23.0 24.0 25.0 26.0 27.0 28.0 29.0 30.0 31.0 32.0 33.0 34.0 35.0 36.0 37.0 38.0 39.0 40.0 41.0 42.0 43.0 44.0 45.0 46.0 47.0 48.0 49.0 50.0
ETH1 KG/HR
Figure 22: Toluene Vs Ethanal in extract stream for 5 stages, UNIFAC mode.
Sensitivity test was repeated for the same variables, using UNIQUAC mode. On
the next page tabulated data.
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Separation processes II
3 STAGES
1780 949.109 23.72184 26.27816 1780 949.1035 26.12244 23.87756
1880 949.0598 24.65211 25.34789 1880 949.0538 27.24526 22.75474
1980 949.0105 25.52951 24.47049 1980 949.0039 28.29413 21.70587
2000 949.0002 25.69364 24.30636 2000 948.9943 28.51686 21.48314
Table 8: Tabulated data for ASPEN simulation n-stages – vary water flow rate, table 1.UNIQUAC mode.
39
Separation processes II
5 STAGES
1780 949.1009 27.33494 22.66506 1780 949.0998 28.02938 21.97062
1880 949.0509 28.58773 21.41227 1880 949.0496 29.34275 20.65725
1980 949.0008 29.7772 20.2228 1980 948.9983 30.61331 19.38669
2000 948.9904 30.00157 19.99843 2000 948.9893 30.91345 19.08655
Table 9: Tabulated data for ASPEN simulation n-stages – vary water flow rate, table 2.UNIQUAC mode.
40
Separation processes II
1850
1650
1450
Water [kg/hr]
2 stages
1250 3 stages
4 stages
1050 5 stages
850
650
450
948.98 949.18 949.38 949.58 949.78 949.98
Tolue ne [kg/hr]
Figure 23: Plot for results toluene Vs water flow rate for UNIQUAC mode.
Bellow collected data for toluene versus ethanal in extract stream for 2, 3, 4,
and 5 stages in UNIQUAC mode.
TOLUEN
949.7
949.6
949.5
KG/HR
949.4949.3
949.2
949.1
6.0 8.0 10.0 12.0 14.0 16.0 18.0 20.0 22.0 24.0 26.0
ETH1 KG/HR
Figure 24: Toluene Vs Ethanal in extract stream for 2 stages, UNIQUAC mode.
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Separation processes II
TOLUEN
949.7
949.6
949.5
KG/HR
949.4
949.3
949.2
949.1
949.0
6.0 8.0 10.0 12.0 14.0 16.0 18.0 20.0 22.0 24.0 26.0 28.0 30.0
ETH1 KG/HR
Figure 25: Toluene Vs Ethanal in extract stream for 3 stages, UNIQUAC mode.
ETH1
30.0
25.0
KG/HR
20.0
15.0
10.0
948.95 949.0 949.05 949.1 949.15 949.2 949.25 949.3 949.35 949.4 949.45 949.5 949.55 949.6 949.65 949.7 949.75 949.8 949.85
TOLUEN KG/HR
Figure 26: Toluene Vs Ethanal in extract stream for 4 stages, UNIQUAC mode.
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Separation processes II
ETH1
30.0
25.0
KG/HR
20.015.0
10.0
948.95 949.0 949.05 949.1 949.15 949.2 949.25 949.3 949.35 949.4 949.45 949.5 949.55 949.6 949.65 949.7 949.75 949.8 949.85
TOLUEN KG/HR
Figure 27: Toluene Vs Ethanal in extract stream for 5 stages, UNIQUAC mode.
2500
2000
Water [kg/hr]
1500
UNIFAC
UNIQUAC
1000
500
0
948.8 949 949.2 949.4 949.6 949.8
Toluene [kg/hr]
Co –current mode
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Separation processes II
For co-current mode, ware run few different run with vary flow of wash solvent,
as well as vary number of stages. Set up for co – current run was as describe:
mixer to which fresh feed and solvent stream ware introduced, was followed by
settler, from which extract was collected at the bottom, and the raffinate from
the top was send it to the nest stage, so in that case to next mixer unit.
Operating conditions ware applied as describe for counter current flow,
temperature= 15oC , and the pressure = 1 atmosphere. Use of Aspen Plus was
based on UNIFAC model. Bellow – next page, general flow shets, and table
results, for 2, 3, 4 stages separation unit with vary water flow rates: 500, 1000,
1500 [kg/hr] respectively.
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Separation processes II
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Table 10: 2 stages co-current mixer – settler separation unit results for 500[kg/hr] water flow rate.
46
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Table 11: 2 stages co-current mixer – settler separation unit results for 1000[kg/hr] water flow rate.
47
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Table 12: 2 stages co-current mixer – settler separation unit results for 1500[kg/hr] water flow rate.
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Table 13: 3 stages co-current mixer – settler separation unit results for 500[kg/hr] water flow rate.
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Table 14: 3 stages co-current mixer – settler separation unit results for 1000[kg/hr] water flow rate.
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Table 15: 3 stages co-current mixer – settler separation unit results for 1500[kg/hr] water flow rate.
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Table 16: 4 stages co-current mixer – settler separation unit results for 500[kg/hr] water flow rate.
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Table 17: 4 stages co-current mixer – settler separation unit results for 1000[kg/hr] water flow rate.
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Table 18: 4 stages co-current mixer – settler separation unit results for 1500[kg/hr] water flow rate.
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20
18
16
14
number of stages
12
co-current
10
counter current
8
0
0 500 1000 1500 2000
water flow [kg/hr]
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EXTRACT
FEED ETHANAL
RAFFINATE
SOLVENT=WATER DISTILLATION
COLUMN
EXTRACTION
COLUMN
WATER
After extraction process, we will have extract containing 99.5% of toluene and
0.5% of ethanal, and raffinate on the bottom of the extraction column
containing 0.5% of toluene, water and 99.5% of ethanal. Raffinate will be sent it
to distillation column for recovery and purification of the ethanal. As water-
ethanal system doesn’t create azeotrope solution, it will be easy to separate.
The boiling point of the ethanal = 20.2 oC, and the boiling point of the water =
100 oC. [11] the feed our raffinate will be introduced to distillation column at
o
temperature of 20 C, liquid at boiling point, with no vapour. Drawing a
equilibrium curve for water – ethanal system, based on the Antoine coefficients
which can be found in chemical engineering books. From the curve we are able
to compute the mass balance on the process. Composition on the top and the
bottom of the column is required, to step off the number of stages required to
achieve specific purity. The stepping off starts at the feed of around 20%(data
taken from Aspen Simulation counter current mode, water flow=480[kg/hr], and
finishing at point giving a distillation composition of 99%(as this is required
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Cp L (Tb − Tf )
q =1+
λ
Where:
Cp L =Specific Heat capacity of liquid
Tb = Bubble point
Tf = Feed temp
λ =Latent heat of vaporisation.
After completing mass balance for distillation column and energy balance,
diameter, and high can be estimate.
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CONCLUSION
As we have seen in the sections above, there are a number of factors affecting
extraction performance. Laboratory and pilot plant testing using actual feed and
solvent help in optimization. The study could often be an iterative cycle
involving laboratory testing followed by process simulation and design. In most
industrial extractors, there is usually a good scope for optimizing solvent usage
and energy consumption. The extraction model, which I used for separation
ethanal/toluene/water is continuous process, counter current mode. The counter
current mode of operation outperforms the co-current mode. This is
demonstrated in a case study presented. This process was chosen because the
system operating with high quantity flow rate. Also I have used vary information
and methods for describing the material balance, designed of extraction column,
flow diagram. The system will operate at ambient pressure and temperature
which will be equal respectively 15oC and 1 atmosphere for the extraction
column. Based on the UNIQUAC Aspen model using binary parameters, which
are determine from experimental data. The same parameters can be used in
multicomponent mixtures of three components i.e. toluene / ethanal / water.
General design process required determination of solvent- water flow [kg/hr],
basic design of the system, number of stages, and equipment required. Based
on the run simulations in Aspen Plus, I will suggest counter current flow with 2
stages centrifugal extractor. As we can see from the results simulation for Aspen
counter current Sensitivity test, the best effectively we will achieve when we will
use 480-580 [kg/hr] of solvent- water, used in two stages step. I will suggest
“Pod” liquid-liquid centrifugal extractor and separator, as seen on the figure on
the next page.
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REFERENCES
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Appendix A
Acetaldehyde specification
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Appendix B
Toluene specification
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