process intensification @ pin nl · sulzer chemtech pin nl meeting | november 10th 2010 | utrecht...

Sulzer ChemtechPIN NL Meeting | November 10th 2010 | Utrecht

Title: Process Intensification In Real Life

Jeffrey FELIX, | Sulzer Chemtech Ltd. | Process Technology

Process Intensification Network NL | November 10th 2010 | slide 2

Sulzer Chemtech

© Sulzer Chemtech Ltd. 2010, all rights reserved – protection notice ISO 16016 – JeF

Introduction of Sulzer Chemtech Process Technology

Process Intensification by combining unit operations

Concrete PI examples with pervaporation, distillation & crystallization technology

Presentation overview

4 x 4,5 m = 18 m

22 m

4.0 m


Sulzer Chemtech


Structured packing Tray Technology

Separators Demisters

Shell Alliance Crystallization Technology

Membrane Technology

Multi-component dosing, mixing and application systems

Random packing

Hybrid Process PlantsMixpac Systems

Process Technology

Mass Transfer Technology

Tower Field Services

Sulzer Chemtech

Maintenance, revamps & installation

Sulzer Chemtech Ltd. Leadership in Products & Applications

Film EvaporationL/L-Extraction

Reactive Distillation


Sulzer Chemtech


Process TechnologyGlobal organization

PT presencePT potential expansions

PT locations

EMA

ASP

SAM

NAM

Canada

USARegional headquarters NSA

Russia

ChinaSwitzerlandGlobal a. regional headquarters EMA/NSA

Brazil

IndiaSingaporeRegional headquarters APA

Netherlands


Sulzer Chemtech


Process Technology Core activities and markets

TechnologiesExtraction, distillation, crystallization, membrane, evaporation, absorption, polymer & reaction technology

Segments Fine & specialty chemical, pharmaceutical process industry, food industry, polymer production

Products and services

Engineering services (conceptual, basic & detail)Customer testing, process validation, production of samples, toll productionProcess equipment, modular plants, skids

Process applications

Solvent recoveryProduct purificationHybrid processes and solutionsTemperature sensitive separationsPolystyrene, PLA, EPS

Key success factors

Solving complex and difficult separation problemsSupplying advanced, highly efficient process equipment and complete plants Extensive experience in combining unit operations


Sulzer Chemtech


Process Technology Unit operations, Products and Equipment

EvaporationFalling film (FFE)Wiped thin film (TFE)Short path (SPE)

Distillation / rectificationStructured packing Random packingTrays

Liquid / liquid extractionStatic columnsStirred columns

Fractional crystallizationFalling filmStatic systemSuspension crystallization

Membrane systemsPervaporation / vapor permeationPressure driven membrane solutions

Unique experience in unit operations


Sulzer Chemtech


Process Technology Development competence

Process Engineering StudiesConceptual design

Process optimizations / debottlenecking

Process synthesis, development and simulation

Test CentreStandard laboratory and pilot equipment for development, pilot and toll processing

Testing and validation of distillation, absorption, crystallization, liquid-liquid extraction, film evaporation and membrane processes as well as reaction, devolatilization and mixing tests for polymeric systems

Process- & Basic EngineeringProcess design, simulation, PFD

P&ID, Basic Engineering

0

0,2

0,4

0,6

0,8

1

0 0,2 0,4 0,6 0,8 1

Mol Fraction Compound (Liquid)

Mol

Fra

ctio

n C

ompo

und

(Vap

or)

MEK

THF

Acetone

i-Propanol

Ethanol

n-Propanol

AQUEOUS AZEOTROPESAQUEOUS AZEOTROPES


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Screening of possible unit operationsExperience / reference units / plantsIn house know howLiterature / databasesProcess simulationBench scale feasibility tests for promising unit operation

Combination of unit operations to most cost effective hybrid process

Validation Process simulationPilot scale tests / sample generation

Basic Engineering

Detail Engineering

Supply of (key)equipment or skid mounted unit

Commissioning of turn key hybrid system

Process Technology Hybrid Approach

0.00.1

0.20.3

0.40.5

0.60.7

0.80.91 0.0

0.10.2

0.30.4

0.50.6

0.70.8

0.91

0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

70.6 °C


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Hybrid Processes Features of specific unit operations

Robust process with high mass transfer rates in liquid and vapor phasePhase separation is rapid and complete

Distillation

Low temperature selective separation @ at mostly ambient pressureHigh throughput @ low energy consumption

Liquid-Liquid-Extraction

Separation at low (melting) temperaturesSeparation of mixtures with close boiling componentsVery high specific purification is possible

Crystallisation

Independent of vapor–liquid equilibriumDirect solvent dehydration of azeotropics and close-boilers without entrainer

Vapour permeation / Pervaporation

No phase transition leads to low energy demandSeparation based on molecule size

Pressure driven membrane (UF/NF/RO)


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Reactive Distillation Processes

Acetate Technology- Synthesis of Methyl, Ethyl & Butyl Acetate- Hydrolysis of Methyl Acetate

Acetalisation- Synthesis of Methylal- Removal methanol from Formaldehyde

Fatty Acid Esters

Feed A

Feed B

Product C

Product D

A + B C + D

Reactor

A + BA + B

(A + B) + C

Conventional Flowsheetfor Reactor and Distillation

DistillationColumn

Reactive Distillation with Pre-Reactor

Reactive distillationColumn

A + B

A + B

C

Reactive DistillationFlowsheet

Reactive distillationColumn

C

Pre-Reactor

A + BA + B

(A + B) + C C

Combine Reaction and Separation in ONE Column

Hybrid Processes and application examplesReactive Distillation


Sulzer Chemtech


F

Meltcrystallization

D

B

A

Distillation

A B

T

y

x

R F

D

A

R

Hybrid Processes Crystallization and Distillation ISeparation of a binary mixture with eutectic and azeotrope


Sulzer Chemtech


Separation of a binary mixture with an eutectic

F

Meltcrystallization

Distillation

B

AS

A B

T

y

x

R

F

B

RS

A

Hybrid Processes Crystallization and Distillation II


Sulzer Chemtech


Hybrid Application ExamplesCrystallization and Distillation

KEY APPLICATIONS

(ultra) high purities

color / odor removal

isomer separation

APPLICATION EXAMPLES

Dichlorobenzene Isomer Separation

Nitrochlorobenzene Isomer Separation

Nitrotoluene Isomer Separation

Chlorotoluene Isomer Separation

Meta-Xylene Purification with Ethylbenzene as byproduct

MDI Isomer Separation and Purification

Bisphenol A Purification

Caprolactam Purification

DMT Purification

Trioxane

Monochloroacetic Acid

High Purity Benzoic Acid

Glacial Acrylic Acid

Glacial Lactide

Naphthalene Purification

Para-tert. ButylphenolPurification

Anthracene/CarbazoleSeparation and Purification


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Lay-out before extension

Hybrid processes Crystallization and Distillation Application example


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Expansion scenario’s



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DISTILLATIONgeneral applicable (if volatile)

proven technology

engineering correlations available

known technology at customer

lab & pilot units available

However

high operating temperature (boiling point >> degradation)

energy intensive

limited purity (VLE depending)

isomer separation difficult

close-boilers difficult to separate

CRYSTALLIZATION

applicable for product

proven, but ‘innovative’ technology

confirmation pilot tests needed

new technology for customer

lab & pilot units available

lower operating temperature (melting-point >> no side reactions)

lower energy consumption

high purity (limited by eutectic point)

no problem with isomer, close boilers or azeotropic separation

Hybrid processes Crystallization and Distillation Pro’s & con’s: why melt-crystallization?


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Summary:

Yield for crystallization of impure mixtures is poor due to phase diagram limitation of the product system

Crystallization from impure mixtures requires multistage operation that leads to larger equipment and higher energy demand

Distillation can, at relatively low energy demand, separate the bulk of impurities easily

Combining the strong points leads to an ideal basis for a hybrid solution and a lower investment @ lower energy consumption

RESULT : HYBRID OPTION CHOSEN AND INSTALLED



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Debottlenecking (Base Case*) Isopropanol Entrainer (azeotropic) Distillation

IPA (99.99 wt%)

T-01 T-02

WATER (99.99 wt%)to sewage

FEED

WATER to sewage

Life Steam (def. as 100%)

Steam (def. as 100%)

Steam (def. as 100%)

Cyclohexane (def. as 100%)

*base model system = process as modeled by Sulzer Chemtech with data from customer

azeotrope87.5 wt% IPA

12.0 wt% IPA

CW (def. as 100%) CW (def. as 100%)

T-03


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Energy Efficient Hybrid System (existing setup with low investment integrated PERVAP™)

IPA (99.99 wt%)

T-02

WATER (99.99 wt%)

FEED

WATER

LS (~ 70% of savings**)

Steam (~ 28% of savings**) Steam (~ 65%of savings**)

IntegratedPervaporation Unit

CH (~ 70% savings **)

** compared to process as modeledby Sulzer Chemtech with data from customer

80-85 wt% IPACW (~ 35% of savings **) CW (~ 68% of savings**)

T-01T-03

12.0 wt% IPA


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Isopropanol recoveryUtility overview

Utility costs (per ton product) Cost Base original with integrated PV

Steam (average) 25 €/ton 100 % 55 %

Cooling Water 0,8 €/m3 100 % 49 %

Total 100 % 52 %

Comparison

energy demand

life steam

cyclohexane circulation

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Reboiler T-01 Condenser T-01 Reboiler T-02 Condender T-02 LPS AmountCyclohexan

Dut

y H

X /

Ste

am /

CH

[%]

originalnew with PV


Sulzer Chemtech


Entrainer volume can be reduced by more than 60 %

Capacity increase up to 35 % possible

Energy savings of 120 € per ton/hr of product:

Annual operation costs PV: ~200’000 Euro/yr

Simple payback for investment of complete pervaporation system: 2 – 3 years including site engineering, civil engineering & works and pervaporation skid

Isopropanol recoverySummary


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AtmosphericColumn T-1

Recycle 3800 kg/h 11.5% H2O

Water 6‘500 kg/h

PressurecolumnT-2(8 bar)

Product 3‘500 kg/h> 99,97 % THF

Feed

10‘000 kg/h35 % THF65 % H2O

Azeotrope 7‘300 kg/h, 6% H2O

Tetrahydrofuran (THF)Base Case : Pressure Swing Distillation


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Tetrahydrofuran (THF)Pressure Swing Distillation with Pervaporation Unit

AtmosphericColumn T-1

3‘785 kg/hr0.9 % H2O

Recycle 285 kg/h 11.5 % H2O

Water 6‘500 kg/h

PressurecolumnT-2(8 bar)

Product 3‘500 kg/h> 99,97 % THF

PervaporationUnit

Azeotrope 3‘985 kg/h, 5.8 % H2O

Feed

10‘000 kg/h35 % THF65 % H2O

Permeate 200 kg/h, >90% H2O


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Tetrahydrofuran (THF)Comparison Heat Balances

Decrease energy consumption or increase capacity with pervaporation

Debottleneck and save energy within the same step

Without PV With PVSteam 4 bara MW t/hr Steam 4 bara MW t/hr

Reboiler T-1 1.78 3.01 Reboiler T-1 1.18 1.99

Reboiler T-2 1.22 2.05 Reboiler T-2 0.30 0.51

PV Stage 0.20 0.34

Total steam 3.00 5.06 Total steam 1.68 2.84

Cooling water 10 °C Δ T MW m3/hr

Cooling water 10 °C Δ T MW m3/hr

Cond. T-1 1.33 114 Cond. T-1 0.58 50

Cond. T-2. 0.91 78 Cond. T-2. 0.21 18

Perm. Cond. 0.14 12

Total CW 2.24 192 Total CW 0.93 80 Production 28.000 t/year > 99.97 wt% THF


Sulzer Chemtech


Thank you for your attention ! Questions ?

Sulzer Chemtech Ltd. Process Technology

Gewerbestr. 284123 Allschwil (Basel), Switzerland

Jeffrey FELIXPhone +31 651 844 [email protected]

www.sulzer.com

Process Intensification by providing superior and competitive hybrid

separation technology solutions with guaranteed performance

mailto:[email protected]

http://www.sulzer.com/

process intensification @ pin nl · sulzer chemtech pin nl meeting | november 10th 2010 | utrecht...

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