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Experimental investigation of the flexible operation of multiple dividing wall columns

Subject Area Chemical and Thermal Process Engineering
Term from 2022 to 2024
Project identifier Deutsche Forschungsgemeinschaft (DFG) - Project number 504053721
 
Final Report Year 2024

Final Report Abstract

Distillation is the most energy intensive and at the same time most used separation process in chemical industry. Estimates predict that the process is responsible for approximately 2.5 to 10 % of the total energy consumption, thus distillation also contributes significantly to manmade climate change. Minimizing this impact is the overall objective of this research project. One approach to increase the efficiency of chemical processes that has been increasingly investigated in recent years is process intensification. In the field of distillation, dividing wall columns are a promising candidate. The present project focuses on multiple dividing wall columns with more than one dividing wall. Multiple dividing wall columns open up the possibility of saving around 50 % energy when separating mixtures of four components/fractions compared to conventional distillation sequences. However, the scientific literature on this topic has so far been limited exclusively to theoretical considerations. In November 2021, however, the world's first multiple dividing column was put into operation at Ulm University. As part of the present project, for the first time extensive experimental validation tests on the operating behaviour of multiple dividing wall columns were carried out. The focus was particularly on the influence of the distribution ratio of the internal flows on both sides of the dividing walls on the achieved separation quality. According to theory, there is a certain operating window within which comparable product purities can be expected. This behaviour has the potential to facilitate stable and reliable operation of multiple partition columns. In fact, the simulatively predicted behaviour could be confirmed in the experiments. The results obtained represent a first important building block for the transition of multiple dividing wall columns to industrial application. Furthermore, the applicant is of the opinion that a major hurdle with regard to the industrial implementation of dividing wall columns is a lack of basic understanding. Therefore, additional fundamental work was carried out to increase the understanding of internal processes in distillation columns and dividing wall columns. The focus was primarily on the temperature profiles that occur during separation over the height of the columns. The profiles can be used to determine whether the separation is working as planned. This knowledge is also of great importance for dividing wall columns, as not just one but three or, in the case of the multiple dividing wall column, even five different separations are carried out simultaneously in one apparatus. In particular, it was worked out how to read the profiles and what countermeasures should be taken if a malfunction is detected. With regard to dividing wall columns, the effects of unfavourable internal flow splits on operation were also investigated in more detail. This knowledge is of great importance to ensure the best possible operation of distillation and dividing wall columns. To substantiate this statement, the findings have already been successfully applied to the pilot plant in Ulm.

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