HEAT FLOWS INTEGRATION OF DISTILLATION AND EPURATION COLUMNS INTO THE PRODUCTION PROCESS OF RECTIFIED ETHYL ALCOHOL

Abstract

Today, ethyl alcohol is widely used in many industries. Ethanol production processes from any organic matter often involve rectification, which is an energy-intensive process. The constant increase in the cost of energy leads to a significant growth of the cost of production. Reducing the unit energy consumption can solve a range of important issues: first, that of decreasing production cost, and secondly, that of nationwide dependence on external energy suppliers. A detailed analysis of the thermal energy potential of technological flows aimed at solving the problem of reducing energy consumption inspires the development of more energy-efficient solutions for organizing this processes.
 The search for alternative solutions demonstrates that one of the methods of reducing the unit energy consumption for ethanol production, in particular one that does not require a total restructuring of the production lines, is the method of integration of processes based on pinch analysis.
 The extraction of these technological flows was carried out on the basis of the regulatory documentation of the hardware-technological scheme of the centralized ethyl alcohol head fraction distillation plant and the energy audit report of that plant, which was carried out at one of the alcohol enterprises of Ukraine.
 A distillation and a purification column were selected from the centralized ethyl alcohol distillation plant for thermal integration of the existing process. The thermal and material balances of the ethyl alcohol head fraction distillation plant columns were calculated.
 To maximize the energy potential of the heat flows, the principles of pinch design were applied and a grid diagram of heat exchanger networks was designed.
 To maximize the recovery of thermal energy, the difference ΔTmin was set to - 3ºC. This led to the need to use energy-efficient heat exchange equipment. A significant reduction in the use of external utilities (by 48% for cold utilitie and by 38% for hot utilitie) for selected heat flows and a short payback period for the project (approximately three months) makes this solution viable.