Distillation Process Research Articles

Enhanced cryogenic distillation column identification for methane separation: a hybrid artificial neural network approach

Abstract Modelling the dynamics of cryogenic distillation columns is challenging due to their complex, nonlinear behaviour. This study introduces a novel identification approach using a hybrid Artificial Neural Network (ANN) optimized with Particle Swarm Optimization (PSO), applied to cryogenic distillation as a case study. The NARX-PSO-ANN model effectively captures the nonlinear dynamics of the distillation process by optimizing model parameters and avoiding local optima. The novelty of this work lies in integrating the NARX (Nonlinear Autoregressive with Exogenous Inputs) architecture with PSO, which enhances robustness and performance. To validate the model’s efficacy, realistic simulations of the cryogenic distillation column were conducted using Aspen Plus Dynamics, generated 2,000 data samples-1,400 training and 600 for validation. The NARX-PSO-ANN model was evaluated against established methods like BP-ANN and NARX-based BP-ANN, consistently outperforming them in identifying cryogenic distillation column dynamics and demonstrating superior effectiveness for complex separation processes. A user-friendly Python-based graphical user interface (GUI) was developed for real-time methane composition prediction, making the model accessible for practical applications. This innovative approach offers a reliable solution for optimizing complex, nonlinear systems in the process industry.

An effective procedure for optimized design of heat pump distillation process

Research on heat pump-assisted (HP) distillation columns, especially those applied to divided-wall column (DWC), is increasing due to their potential for energy savings in distillation processes. HP systems offer various configurations and multiple decision variables, which increase computational demands across different distillation systems. In this contribution, a heat pump superstructure (HPS) method is developed and proposed that includes five common HP configurations. Combined with an improved differential evolution algorithm, the optimal HP structure in multiple configurations for different optimization tasks is automatically computed. The advantage of HPS method is that it could be incorporated in distillation columns to systematically and simply find an optimum configuration for various separator systems and separation tasks. The HPS effectively achieves optimal design configurations for binary columns, three-component DWCs, and four-component KDWC separation systems under varying pricing standards.

Economic and environmental assessment of reactive distillation process for cyclohexanol production with different purity intermediates

Economic and environmental assessment of reactive distillation process for cyclohexanol production with different purity intermediates

Interpretable Machine learning model for predicting Ethane-Ethylene composition in binary distillation process

Interpretable Machine learning model for predicting Ethane-Ethylene composition in binary distillation process

Heat integrated extractive coupled pressure-swing distillation with dividing wall column technology for separating phenol/pyridine from coal gasification wastewater

The phenol and pyridine of coal gasification wastewater (CGW) are extremely toxic pollutants. Thus, there is an urgent need to develop a new process for the effective treatment of phenol and pyridine in CGW. Vapor-liquid equilibrium (VLE) and COSMO-SAC model analysis were used to select the entrainer, and interaction region indicator analysis was applied to elucidate the separation mechanism. Aiming to minimize total annual cost (TAC), the optimal process parameters were established through a sequential iterative procedure; extractive pressure-swing distillation process: separation sequence E (EPSDP-SE) process exhibiting the best performance. Heat integrated extractive pressure-swing distillation with dividing wall column process: separation sequence E (HI-DWC-EPSDP-SE) was developed by integrating a thermal process and dividing wall distillation technology. In comparison to EPSDP-SE, HI-DWC-EPSDP-SE achieved reductions of 26.97% in TAC, 38.89% in total operation cost, and 6.21% in total capital cost. Additionally, it lowered total acid gas emissions and energy consumption by 39.98% and enhanced thermodynamic efficiency by 54.72%. The HI-DWC-EPSDP-SE process showcases exceptional separation performance in terms of economy, energy consumption, and environmental impact.

A comparative analysis of differential evolution and Boltzmann-based distribution algorithms with constraint handling techniques for distillation process optimization

A comparative analysis of differential evolution and Boltzmann-based distribution algorithms with constraint handling techniques for distillation process optimization

Formulation & Evaluation of Perfume based on Herbal Oils: A Review

Abstract: Essential oil from lavender flowers and tea tree leaves was extracted using the processes of distillation, maceration, and steam distillation. Perfume extraction is the process of removing aromatic components from basic materials. In order to create a natural perfume, this study set out to extract essential oils from particular fragrant and therapeutic plants, flowers, and leaves. Aromatic essential oils are derived from plants in the Myrtaceous family, such as lavender and Melaleuca alternifolia. Aromatic essential oils are mostly composed of linalool, 1,8-cineole, linalyl acetate, α-terpinene, γ-terpinene, α-terpineol, terpinen-4-ol, p-cymene, and α-pinene. Numerous studies have also been conducted to ensure that it is safe for human use and to lessen the likelihood of instability and discomfort. One of lavender's main advantages is its ability to encourage calm without making people feel sleepy. By regulating the body's fight-or-flight reaction, lavender not only promotes mental serenity but also lowers anxiety. Lavender essential oil has demonstrated efficacy in lowering stress, while tea tree oil has relaxing properties that aid in relaxation, stress relief, and improved sleep quality. Research has shown that aromatherapy can help reduce tension, and tea tree oil is a very useful essential oil for this purpose. To create a natural scent for body splashes or air fresheners, you can substitute some essential oils for others. However, it is essential to perform more toxicological analyses on the product before proceeding

Azeotropic formic acid-water separation by sulfolane extractive distillation feasibility study

ABSTRACT Due to the formation of an azeotrope at 57.6 mol.% formic acid under atmospheric pressure, conventional distillation is ineffective for separating formic acid and water into pure components. This study explores the use of extractive distillation with sulfolane as a solvent to overcome this limitation. The binary interaction parameters for the formic acid-water and sulfolane-water systems were determined using the NRTL model in Aspen Plus V10 software, based on experimental data. The investigation focuses on the effect of varying solvent concentrations on the thermodynamic equilibrium and the relative volatility of water to formic acid. The proposed process design incorporates two sequential columns: an extractive distillation column and a solvent regeneration column, both operating under reduced pressure. Simulation results confirm the feasibility of this method for purifying formic acid. For water concentrations between 80% and 50%, the boiler energy consumption in the extractive distillation process decreases by 42%. The regeneration column operates at 0.254 bar to minimise corrosion and ensure complete recovery of sulfolane. This study highlights the effectiveness of extractive distillation with sulfolane, achieving a high recovery rate of nearly pure formic acid.

Phase Evolution of Molybdenum Concentrate During the Vacuum Distillation Process

This paper presents a method for purifying molybdenum concentrate through vacuum distillation and examines the phase evolution of MoS₂ during the process. First, the forms in which impurities exist in molybdenum concentrate and the feasibility of their volatilization are analyzed, while the structural changes of MoS₂ in a vacuum environment are discussed and verified through theoretical calculations. Next, experiments are conducted to study the effects of holding temperature, holding time, and other influencing factors on the transformation process of the molybdenum concentrate. The feasibility of impurity volatilization and the structural evolution of MoS₂ are further evaluated through experimental analysis of the condensates and residues in the temperature interval of 1273 K–1623 K. The results demonstrate that impurities can be effectively removed without compromising the natural structure of MoS₂.

Mezcal Characterization Through Sensory and Volatile Analyses

Mezcal is a traditional beverage with relevant cultural and economic importance in Mexico, with different Protected Designation of Origin locations. This study focuses on creating a sensory lexicon for Mezcal with local producers by means of Free Choice Profiling. A selection of the most relevant descriptors was made to construct a sensory wheel. Subsequently, a sensory panel evaluated a total of 10 Mezcal samples using the sensory categories defined in the sensory wheel. Additionally, gas chromatography with mass spectrometry was performed to analyze volatile components’ contribution to the aroma and flavor descriptors. A total of 87 terms were selected for the sensory wheel, using 41 descriptors within 10 categories for odor modality and 46 more within 13 categories for flavor modality. The main volatile compounds that were identified were 37 esters, 17 alcohols, 12 ketals and 9 terpenes, which were the foremost contributors to the presence of several sensory descriptors and were also found in most of the Mezcal samples. The quantitative analysis results exhibited a higher floral odor for Mezcal of the Angustifolia variety and the highest smoked odor for an earthenware distilled Mezcal, thus proving that the selection of the descriptors from the wheel was appropriate for differentiating Mezcal samples from different origins, agave species and distillation processes. Therefore, the sensory wheel developed in this study can be used both as a quality control tool and as a marketing tool that allows producers to differentiate their products in the market.

Guidance for Increases Production Capacity of Citronella Oil Gema Industri Farmers Group

Lemongrass (Cymbopogon nardus. L) is a type of essential oil plant whose essential oil is obtained from the leaves and stems of lemongrass. Lemongrass is classified as a medicinal plant with active compounds that can be used as medicine. The lemongrass oil distillation technique carried out by the Gema Industri farmer group uses the water distillation method. The water distillation method carried out by the Gema Industri farmer group using iron drums can affect the quality of the lemongrass oil produced. An inefficient cooling system (condenser) causes product loss because the components of lemongrass oil are volatile or easily evaporated so that it greatly affects the quality of the distillation results. The purpose of community service is to improve the design of lemongrass oil distillation equipment using a steam distiller made of stainless steel with science and technology input and improve the cooling installation to increase the yield of lemongrass oil. Community service activities are carried out in 4 stages, including socialization, training in preparing raw materials, training in distillation based on stainless steel steam distiller technology and the Bottle Packaging Design Training stage. The use of a steam distiller using a steam method made of stainless steel with a distillation process carried out for 4 hours. The time needed for the oil to come out of the distillation results is 1 hour after the distillation process is carried out. The yield of oil produced is 1.2301%.

Distillation plant performance implications of high distillate-purity during ethanol-water pre-concentration

This paper presents the effect of distillate purity on the performance of ethanol-water distillation column before azeotrope. The factors affected include the required number of stages, reflux ratio, reboiler and condenser duties, investigated using different feed thermal conditions. The model was set using Aspen Plus® V10 simulation software and used to establish the impact of operating conditions due to high distillate purity. The aim was to increase distillate purity while minimizing energy consumption. The research highlights the importance of modeling and simulation for optimizing distillation processes to reduce energy consumption. The feed flow rate was 1000 kmol/h, with composition ranging from 0.1 to 0.6 mol/mol. The number of stages varied from 8 to 20 while the reflux ratio ranged between 1 and 8. The required number of stages, reflux ratio, condenser and reboiler duties increased with increasing desired distillate purity. The reboiler and condenser duties increased with distillate purity according to 3rd order polynomial functions. It was concluded that the pre-concentration column can concentrate dilute solutions to higher purity closer to the azeotropic point. Further studies were recommended on the non-linear behavior and large energy consumption.

The influence of feed molar flow rate on key streams properties and duties in ethanol-water azeotropic distillation process

Investigation on the influence of near azeotropic feed molar flow rate on properties of key streams connecting main process units of an ethanol-water azeotropic distillation pilot processis presented. The heterogeneous azeotropic distillation model with cyclohexane entrainer was configured in Aspen Plus® V10 commercial simulation software. Property analysis and prediction of plant’s performancewere achieved using Non-Random Two Liquid Redlich-Kwong thermodynamic model. Both residual curve maps and ternary diagrams were used to determineseparation possibility and presence of ethanol-water azeotrope in the formed ternary mixtureduring distillation synthesis. The process convergence was addressed using flowsheet convergence and balance node. Distillation of ethanol- water azeotropic mixture was simulated at constant recycle ratio (R = 5), numberof stages (N = 12) and pressure (P = 1 atm). Data obtained were analysed in MS Excel 2013. Results showed that simultaneous increase ofmolar flow rate of the near azeotropic feed and feed ethanol concentration improves ethanol purity but results in retrograde phenomenon which may humper plant’s performance and increase stream flow rates and therefore increase energy duties. The condenser duty of the main column wasaround 90.94% higher than the recycle column’scondenser duty. Also, reboiler duty of the main column were nearly 90.25% higher than the recycle column’s reboiler duty.It was concluded that setting 18 to 20 kmol/h feed molar flow rate enhances higher energy efficiency and improves ethanol product purity. Careful distillation synthesis and plant’s monitoring are recommended to improve ethanol-water azeotropic distillation plant’s performance and address retrograde phenomena.

The effect of reflux ratio and feed thermal conditions on ethanol-water distillation process performance

Demand for ethanol has increased globally due to the need for energy and consumer chemicals, necessitating use of distillation to concentrate dilute sources. This paper presents the effect of reflux ratio, number of stages, feed thermal conditions (FTCs), feed composition (XF), and feed plate location on the performance of a normal distillation column separating ethanol-water mixtures ranging between 0.1 and 0.6 mol/mol. The model was created using Aspen Plus® Software. The FTCs studied include: feed at room temperature (FRT), partially vaporized feed (PVF), feed at its boiling point (FBP), superheated vapor (SHV) and feed at dew-point (FDP). The performance factors studied were: distillate composition (XD), reboiler and condenser duties. The axial profiles of temperature and ethanol concentration in the liquid across the column revealed stronger dependence on XF in the stripping section and on feed plate location. Increasing reflux ratio increased distillate composition, reboiler and condenser duties. Increasing feed composition increased distillate composition and lowered reboiler and condenser duties depending on the FTCs. Locating the feed plate further down the column increased the distillate composition. The QR was highest for FRT while QC values were highest for FTC and SHV. The FBP led to minimum energy demands for both QR and QC. To minimize energy, switch all FTCs to FBP was recommended, with highest savings observed for switching from FRT to FBP.

A Gate-Opening Control Strategy via Nitrate-Chloride Anion Exchange for Enhanced Hydrogen Isotope Separation in Metal-Organic Frameworks.

Efficient separation of hydrogen isotopes, especially deuterium (D2), is pivotal for advancing industries such as nuclear fusion, semiconductor processing, and metabolic imaging. Current technologies, including cryogenic distillation and Girdler sulfide processes, suffer from significant limitations in selectivity and cost-effectiveness. Herein, we introduce a novel approach utilizing an imidazolium-based Metal-Organic Framework (MOF), JCM-1, designed to enhance D2/H2 separation through temperature-dependent gate-opening controlled by ion exchange. By substituting NO3⁻ ions in JCM-1(NO3⁻) with Cl⁻ ions to form JCM-1(Cl⁻), we precisely modulate the gate-opening threshold, achieving a significant enhancement in isotope selectivity. JCM-1(NO3⁻) exhibited a D2/H2 selectivity (SD2/H2) of 14.4 at 30 K and 1 bar, while JCM-1(Cl⁻) achieved an exceptional selectivity of 27.7 at 50 K and 1 mbar. This heightened performance is attributed to the reduced pore aperture and higher gate-opening temperature resulting from the Cl⁻ exchange, which optimizes the selective adsorption of D2. Our findings reveal that JCM-1 frameworks, with their tunable gate-opening properties, offer a highly efficient and adaptable platform for hydrogen isotope separation. This work not only advances the understanding of ion-exchanged MOFs but also opens new pathways for targeted applications in isotope separation and other gas separation processes.

Influence of pH and Sulfur Dioxide in Unaged Wine Distillates on the Physicochemical and Sensory Profile of the Brandies de Jerez

AbstractBrandies are spirits produced from wine spirits and wine distillates aged in less than 1000 L oak casks for at least 6 months. The composition of each brandy is determined by its raw material and its aging. During aging, two different phenomena occur: the extraction of compounds from the cask wood and reactions between the different compounds. Characteristics of the casks have a significant impact during this process. Those casks that have previously contained some type of Sherry wine give rise to the so-called Sherry Cask®, which not only contributes to the compounds from the wood but also to those that were originally found in the Sherry wine previously aged in them. The quality of brandy is also determined by the physicochemical composition and characteristics of the distillate, which depends both on the quality of the distilled wine and on the distillation process itself. This work studied the effect of sulfur dioxide and the role that the pH of the distillate plays on the physicochemical and sensory composition of three brandies aged 24 months in a static system of Sherry Casks®. The analyses were carried out following the OIV methods. Results have revealed that high levels of sulfur dioxide and the distillate pH significantly condition the extraction of phenolic compounds and organic acids from the wood, as well as reactions such as hydrolysis or esterification that take place between the compounds in the spirits. These factors have led to a differentiated sensory evaluation of the final brandies.

Separation Process for Methanol–Methylal–Methyl Formate Multicomponent System in Polyformaldehyde Production Waste Liquid: Modeling and Techno-Economic Analysis

The vapor–liquid equilibrium (VLE) data of the ternary system methanol–methyl formate–methylal was measured at atmospheric pressure using a modified Rose equilibrium kettle with vapor–liquid double circulation method. The experiment data were correlated with the NRTL, UNIQUAC, and Wilson activity coefficient model equations. The results shown that the root mean square deviation (RMSD) between the calculated and simulated values of the three models followed the order: UNIQUAC ≈ NRTL < Wilson, and except for the RMSD (T) in the range of 0.4–0.5, the others are less than 0.01. In addition, the NRTL model was selected to link with Aspen Plus software to simulate the separation process of polyformaldehyde (POM) waste liquid. The simulation results show that the methyl formate in POM waste stream can be purified by simple distillation, while the methylal separated from the POM waste liquid, which was affected by factors like the azeotropic behavior of binary components, necessitates a complex distillation process. Under optimal operating conditions, the recovery yield of methyl formate through direct distillation can reach 99.7%, with an economic benefit of 6960.1 CNY per ton of waste liquid. Although the economic benefit of the multi-component distillation reach 7281.2 CNY, the increase in the number of equipment and the complexity of the process have negative impacts.

DYNAMIC SIMULATION INTEGRATION IN PROCESS CONTROL EDUCATION: A CASE STUDY ON METHANOL-WATER SEPARATION USING AVEVA PROCESS SIMULATION

This study explores implementing a novel teaching methodology for process control education using AVEVA Process Simulation software. The methodology integrates interactive simulations and practical problem-solving exercises, focusing on the dynamic simulation of an ethanol-water distillation process. In this scenario, students are tasked with evaluating the performance of controllers integrated into the simulation, allowing them to engage with dynamic process behaviors in a virtual environment. The results indicate a significant improvement in students' understanding and assimilation of process control concepts. Feedback gathered through questionnaires, with six participants, highlighted the effectiveness of the adopted methodology. All six participants reported an enhanced understanding of PID controller tuning (average score of 4.83), demonstrating the positive impact on both practical and theoretical learning. This innovative teaching strategy demonstrates its potential to modernize process control education and bridge the gap between academic instruction and industrial applications.

Optimization of the production of grade A liquid smoke from Patchouli solid residue using a distillation-adsorption process

<p>Patchouli cultivation in Lhokseumawe, Aceh Province, produces a significant amount of biomass, with approximately 96%–98.5% of the raw material ending up as solid residue after the oil distillation process. This waste is often discarded or burned, leading to environmental problems. However, this residue is rich in compounds derived from the breakdown of lignocellulose and can be pyrolyzed to produce liquid smoke. Liquid smoke contains valuable phenols, acids, and carbonyls but may also generate harmful byproducts such as polycyclic aromatic hydrocarbons (PAHs). This study aimed to optimize the production of grade A liquid smoke through purification using a distillation and adsorption process. Pyrolysis of patchouli residue was conducted at 400 ℃ to produce liquid smoke. Furthermore, the raw liquid smoke was purified by distillation and adsorption. The distillation process was conducted at a temperature range (X<sub>1</sub>) of 150–200 ℃ for 30–90 min (X<sub>2</sub>). The weight of activated biochar used during the adsorption process varied between 5 and 15 g (X<sub>3</sub>). The experimental design was carried out using Design Expert version 13. Research findings indicate that the optimal condition for liquid smoke was achieved with the equation Y = 1.26 + 0.53X<sub>1</sub> + 0.0319X<sub>2</sub> + 0.8023X<sub>3</sub> – (4.91X<sub>1</sub>)<sup>2</sup> – (0.0015X<sub>2</sub>)<sup>2</sup> – (0.2147X<sub>3</sub>)<sup>2</sup> – 0. 0644 X<sub>1</sub>X<sub>2</sub> – 0.0327X<sub>1</sub>X<sub>3</sub> + 2.15X<sub>2</sub>X<sub>3</sub>. The best results were obtained at a distillation temperature of 175 ℃, a duration of 90 minutes, and using 13.4 g of activated carbon, which resulted in a high total phenol yield of 8.06%. The produced liquid smoke was classified as grade A, with a yield of 74.33%, a density of 0.9928 g/m³, a viscosity of 1.6203 cP, and a pH of 3.32. This research highlights an eco-friendly solution for valorizing patchouli waste, transforming it into a product with a wide range of applications as a food preservative, flavor enhancer, and medicinal agent.</p>

Nipa-based bioethanol as a renewable pure engine fuel: A preliminary performance testing and carbon footprint quantification

The need for alternative fuels remains a growing concern in alleviating the depletion of fossil fuels for transportation to address one of the objectives of the Sustainable Development Goals (SDG 7: Alternative and Clean Energy) despite the emerging use of Electric Vehicles. Nipa fruticans has been introduced as a promising feedstock for bioethanol production, but its performance as a pure engine engine fuel must be determined, and its carbon footprint must be quantified to assess its impact on the environment were this paper aimed. The CO2 emissions of this study was quantified using ISO 14040 methodologies, considering direct and indirect emissions from production to utilization with key ethanol properties tested according to ASTM standards. A carbureted motorcycle was modified to a fuel injection (FI) system to assess fuel performance, with metrics like power output, consumptions, and emissions were evaluated. Results show that nipa-based bioethanol, H95F and H99F, can serve as renewable pure engine fuels, with carbon footprints of 0.2353 and 2.633 kg CO2eq per Liter respectively with 1.08% lower of kg CO2eq per Liter emissions and 32.7% lower production cost compared to fermented sugar. As pure engine fuel resulted in lowering CO emissions by 171.79% and 167.59%; and lower HC emissions 172.89% and 191.34% respectively compared to E10. These findings demonstrated the potential of nipa bioethanol as a clean and sustainable energy solution. It is recommended however that ethanol yield and distillation process be further improved and explore pure ethanol as alternative fuel to hybrid vehicles as 100% renewable vehicles.