OVERVIEW OF CYCLIC DISTILLATION SYSTEM

CYCLIC DISTILLATION SYSTEM

Cyclic distillation process has following phase interaction mode - while the vapor passes through the column, the liquid doesn’t flow from tray to tray, and if the liquid flows over, it is not mixed on adjacent trays. In this case, the liquid flow (feed, reflux, distillate and bottom product) moves in a continuous mode. This method was named the controlled cyclic mode. Cyclic distillation operation consisting of two key parts: vapor flows goes through the distillation column and the stationary liquid stays on the trays (Fig. 1a), and this is called the vapor flow period, while the liquid flow period arises when vapor flow is stopped and the liquid holdup in sluice chambers (Fig. 1b), the vapor flow period starts and liquid from sluice chambers falls into the tray below (Fig. 1c).

➽ The time interval from the start till the finish of vapor supply is called the vapor period (VP) and the time interval from the start till the finish of liquid flow – liquid period (LP). The time of each liquid and vapor phase flow is, in total, the full time of cycle (TC):

TC=VP+TC                                                                                                                              (1)

➽ The design algorithm of a Maleta tray is as follows: the requirement as to the absence of liquid overflow on the trays during vapor supply is performed on hollow type trays while the vapor speed exceeds the column flooding. The requirement as to the absence of liquids mixing on adjacent trays during liquid overflow is ensured by means of a sluice chamber located under the tray. Cyclic distillation column works in the follow way: liquid flows (feed, reflux) are continuously supplied to the tray. 

➽ During vapor supply, the liquid doesn’t overflow from tray to tray for the speed of vapor in the column exceeds the column flood speed. The controlling influence on liquid overflow from tray to tray is exercised by vapor, the cut in the supply of which for a couple of seconds allows the liquid to overflow from the tray bubbled cloth to the sluice chamber. Subsequent vapor supply opens the sluice chamber and the liquid flows to the empty tray below. Such sequence of actions takes place synchronically on all trays on the column’s height. 

Innovation & Distillation Service

Maleta cyclic distillation llc is implementation of turnkey solution for distillation, reactive distillation, stripping & absorption. Our company manufacturing process equipment at the Ukrainian and Estonian factories according Ukraine, Russia, European and American standards.

Technology innovation

Technological capabilities of our distillation column significantly exceed the capacity of conventional columns. Our column has resulted in a 3 to 4 times more efficient separation of components and reduction energy consumption at 20…35% into the process. Technology innovation approved by USA, European, Eurasian, Russian and Ukrainian patents, International Congress and Publications.

Key economic benefits from cooperation with our company  

·         Lower investment cost 20…50%

·         Lower hot energy consumption 20…35%

·         Lower cold energy consumption 20…35%

·         Improvement of product quality

·         Increase of product yield

·         Environment enhancement

List of Service and Equipment

·         Pilot plant testing of separation process

·         Basic and detail design

·         Industrial automation and control solution

·         Supplier of mass transfer equipment

·         Reconstruction of the existing column

·         Installation and commissioning work

·         Staff training

·         Project management

·         After sales service

Market application

Increased interest to cyclic distillation technologies at ethanol, chemical, petrochemical, oil refining, gas processing, organic synthesis, pharmaceutical, and other industries.

Renovation of White Spirit Plant

Our company proposes two cases of revamping existing white spirit production. First case – we fully revamp existing technology. Second case – we are installation additional equipment for current white spirit system. The volume of revamping deepens from correct technology. As result of revamping we remove small and aromatic from white spirit and factory produce low aromatic white spirit according international SGS certification.  There are no problems with application different raw materials (quality of kerosene). 

 Our system provides to optimum yield and quality of white spirit, operation 8/24 or 24/7 (batch and continuous operation modes). Our turn-key white spirit plant solutions have individual design. We supplier advanced techniques solution that give to you opportunities have leading position on the market

Dividing Wall Column

Cut Capital and Energy Cost of your Next Revamp with Dividing Wall Column. Renovation Service

➽ Our company specializes in developing, designing and implementation of mass transfer equipment and engineering systems. Our equipment always designed and manufactured in an optimal ratio price / quality and with using the latest advances in science and technology. 

Benefits of Cooperation with Maleta cyclic distillation LLC: 

• Our clients receive highest profitability of the production with minimal financial and time investments 
• Improving product quality and reduce waste production
• The reliable operation of equipment with wide range of capacity
• Using our technology “cyclic distillation process” will allow provide the leading position in the market

➽ The combination of our knowledge, experience and scientific innovations enable us to provide our customers with unique solutions and maximize the financial profitability 

➽ One of our cases of service is replacement service. It is include: feasibility studies, column and tray design, process simulation, pilot plant testing, plant optimization, installation, start-up and staff training, guaranty service. 

➽ Today, for our client we will propose - transform your traditional two-column system to one dividing wall column. Maleta cyclic distillation is propose new solution in dividing wall column (DWC) technology – to use our high efficiency tray dividing wall columns. DWC technology represents a mechanical implementation of fully thermally coupled distillation that not only saves significant amounts of energy but is both more efficient and cost effective than conventional distillation methods.

➽ Thus the choice for your technology process a Maleta tray dividing wall column for today it‘s not really a risk, neither for construction nor for plant operation.

Renovation your Conventional Two-column System to One Dividing Wall Column

 Dividing Wall Column

➽ One of the more effective methods renovations of existing distillation columns is using DWC technology, in this case we have reduced capital and energy costs compared to a traditional two-column system. 

➽ Maleta cyclic distillation LLC is propose to renovation existing two columns in your technological process for one DWC-column using Maleta distillation trays. As result of renovation you will get energy saving up to 30%; minimum project investment; efficient use of all existing equipments (heat exchangers, condensers, reboilers, tanks, pumps and others instrumentation ); minimum time of renovation; improvement of product quality; increase of product yield. Our trays in dividing wall column have any geometric configuration and the uniform arrangement of liquid on the distillation tray.

➽ We supply only proven technology solutions for your production. It include: feasibility studies for energy saving and purity improvements of final products; column simulations and design; pilot plant testing; plant optimization; installation or supervision; start-up work; staff training; guaranty service.

Distillation Colum Revamping

Reduce your column high at 2.0 times and energy consumption at 30 % with Maleta Trays. Distillation Column Revamping

➤ Modern requirements to the distillation process are more stringent energy consumption and the quality of the final products. Many of existing distillation column being revamped to more efficiency that gives opportunities to have energy saving, improvement of product quality and increase of product yield.  Some of columns should be absolutely revamped for new one and some of them can be change column internals. In case of revamping column internals/trays we can use existing installation, heat exchangers, condensers, reboilers, tanks, pumps and others instrumentation. Column revamps need individual approach and should goes step-by-step.

➤ Maleta cyclic distillation LLC is propose to revamping your column internals to high efficiency Maleta trays. As results you will have: reduce column high at 1.5 … 2.0 times; reduce energy consumption at 20… 30 %; improvement of product quality; increase of product yield. Innovation design of trays provides simpler and faster revamping and more stability operation. 

 
➤ Our services are included: plant audit, simulation and optimization; pilot plant testing feasibility studies; individual solutions; process integration; design and manufacturing of Maleta distillation trays; installation; start-up; staff training; guarantied and post-guaranteed service.

Thank you for visiting our booth and lecture at ACHEMA 2015

✹ From 15-th to 19-th June 2015 - Frankfurt am Main, Germany our company pass exhibition stand at Groups Research and Innovation at ACHEMA 2015.

➽ It was our pleasure and honor and we enjoyed many inspiring conversations. We have been impressed by the number of visitors and the great interest in our cyclic distillation technology, especially for operation principle and technological benefits of our system. By Dr. Bogdan Maleta held a lecture at section Energy Efficient Processes - “Open new opportunities of distillation columns through cyclic distillation technology”. 

➽ At our booth at ACHEMA 2015 we presented cyclic distillation column (cold stand) that have has 5 distillation trays. It was demonstrated key technological benefits of our cyclic distillation like: reduction of the residence time of liquid in the column; the uniform arrangement of liquid on the tray; ability to control the amount of liquid on the tray; placement any type of packing between trays for rise mass transfer efficiency. 

➽ Partition bubbling layer on height; the pressure drop in the column does not depend from change liquid load in the column, since the amount of liquid on the trays is constant; and others.  If you have further questions or you wish more information about our technology and services, please feel free to 

Contact us at mail:  info@maletacd.com  ✉

Give us a call on    +38 050 178 555 0    ☎

Maleta cyclic distillation LLC has presentation stand at the ACHEMA 2015 - Hall 9.2 Stand D76

From 15-th to 19-th June 2015 - Frankfurt am Main, Germany our company at Exhibition Groups Research and Innovation has presentation stand with cyclic distillation column.  We invitation you visit our stand and get acquainted with all benefits of Cyclic Distillation Technology: lower investment cost; lower hot energy consumption; lower electricity energy consumption; improvement of product quality; increase of product yield.

Pilot Plant Testing of Distillation Process

Our industry-pilot distillation system is available for testing feed stocks in temperature range from 50°C to 320°C in vacuum, atmosphere and pressure for absorption, distillation and reactive distillation. On the basis of these tests we get the full scale design, products quality and yield.  All these results are guarantees for a future successful project implementation.  As results of co-operation with our team you will get most efficiency and profitable solution for your project. 

Our pilot distillation column has 21 trays with column diameter 325mm. Power 60 KW. The pressure range is 5kPa - 1MPa. Liquid flow range is 0.2 – 1 m3/hr. Operation modes are: stripping column; stripping column without selection of the bottom liquid; rectification part of column; rectification column at infinite reflux Ratio (R=∞). 

The high level of competition in business gives a high rate of improvement of production processes with a constant increasing of the quality of the products and reducing of their costs. The leadership position in the market could be provided by permanent scientific research development.

Turning the Fuel Grade Ethanol into Food Grade Ethanol via Cyclic Distillation Columns

Today for fuel grade ethanol plant with big capacity there is a cost effective solution - the part of plant capacity converted to production of ethanol food grade. For fuel grade ethanol plant that uses as raw materials wheat/corn our company proposes technology solution in turning the fuel grade ethanol into food grade ethanol. We are doing audit of existing fuel grade ethanol plant and adapted our technology to the current production and customer requirements. To turning the fuel grade ethanol production into food grade ethanol is necessary adding additional distillation columns in distillation department.

Cyclic Distillation Columns

For cleaning ethanol from impurities we will use innovation technology of cyclic distillation. This innovation confirms by patens of USA, Europe, Russia and others countries. Mass transfer efficiency of cyclic distillation in 2…3 time height that classical distillation. The number of distillation tray in 2…3 less that classical.

Maleta cyclic distillation LLC has great experience in production high quality ethanol food grade. The main indicators of quality are organoleptic and physical chemical properties. In production high quality ethanol food grade we use many of know-how and highly effective distillation columns.

Distillation Trays + Structured Packing Enable to Partition Bubbling Layer on Height and Increase Efficiency

Tray column and  packed column widespread use in chemical, petrochemical and other industries to separate liquid mixtures. Today, high efficiency of mass transfer is one of key factors influencing the choice of column type. Our company proposes additional increasing mass transfer efficiency by placement structured packing between distillation trays.

Most efficient using of the structured packing is achieved in a flooded her condition, in the mode of emulsification. In this case, increases the mass transfer area and the volumetric mass transfer coefficient is 2-3 times. Cyclic distillation technology is able to raise efficiency of mass transfer due to the location structured packing between the Maleta trays. For cyclic distillation there is no fluid motion at the tray, as result we have effect of partitioning the bubble layer by height.

Technological advantages: 

·        Possibility to set structured packing between the trays (including a fluidized  layer);

·        The increase in the volume mass transfer coefficient is 2-3 times;

·        Partition bubbling layer on height. 

Cyclic distillation technology gives opportunities to combine all the advantages of tray and  packed column.

Tray Divided Wall Distillation Column Your Effective Solution

Nowadays distillation process despite its high energy consumption is the main separation technique in ethanol, pharmaceutical, petrochemical and chemical factory. The divided wall distillation column (DWC) and is considered a very attractive solution for reduction of energy and investment in separation distillation.

Maleta cyclic distillation LLC in 2014 year build first tray divided wall distillation column DN 1500/1700 mm that operation in cyclic mode. The cyclic distillation technology has opportunity to combine the required number of columns for the separation of multicomponent mixtures in a one column and have advantages over usual parked DWC-columns:

• price of tray dividing-wall columns is much lower than common DWC-column;
• better process control
• simpler column design;
• the uniform arrangement of liquid on the tray;
• faster and more precise installation;
• mass transfer efficiency of cyclic distillation;
• faster and simpler revamping of existing column.

We propose next configurations of the tray dividing-wall columns: azeotropic dividing-wall columns; reactive dividing-wall columns; extractive dividing-wall columns; dividing-wall columns for four-component mixtures.

Our company supplies full engineering service for DWC technology - simulation, design, manufacturing, additional project equipment, chef installation, guaranty and post-guaranty service.

Demethanl column in production ethanol food grade

At the ethanol plant that production ethanol food grade, with capacity 30 000 liters per day was problem with methanol content in final product (high methanol levels). Maleta cyclic distillation LLC proposes to install addition high efficiency column in cyclic mode for concentration methanol less than 5 ppm in the final product. 

Column feed is unpasteurized ethanol from rectification column (ethanol distillation column) in the amount 7…10 % of plant capacity. Steam consumption of cyclic methanol column is about 0.5 kg / L of input ethanol. The bottom liquid from methanol distillation column goes as additional feed to rectification column (ethanol distillation column), and the concentrate in the amount of 0.2…0.3 % remove like waste.

The additional cyclic methanol column has next characteristic: column diameter 400mm, number of Maleta distillation trays 15psc. The stripping section of distillation column consists of 9 distillation trays - the concentration section of 6 distillation trays.

The final results of reconstruction are: the concentration methanol is less than 5 ppm in the final product; reduces of content of aldehydes in ethanol food grade; increases the oxidation of ethanol food grade; improves the organoleptic characteristics of ethanol food grade.

Catalytic Cyclic Distillation Column for production Isopropyl Alcohol (IPA) from Propylene

Catalytic Distillation Column

The conventional technology of production Isopropyl Alcohol (IPA) from Propylene is direct hydration and indirect hydration of propylene. Separation of IPA from the azeotropic mixture need list of distillation columns and high steam consumptions. In recent years, much research has been paid to by innovation, effective and simple method for production Isopropyl Alcohol (IPA) from Propylene – catalytic (reactive) distillation. The catalytic distillation column comprises the processes of heterogeneous catalytic reaction and multistage distillation is carried out simultaneously in one unit. In this case, we have reduced of capital and operation cost, because the number of process equipment is considerably reducing.

The key benefits of cyclic distillation in comparison with the stationary process is control of the reaction time, and increase in performance of the distillation column by minimizing the flow resistance in the cross-flow of liquid from the tray on a tray (single-phase fluid flow). The catalyst can be placed between the trays in a boiling layer.

Maleta cyclic distillation LLC propose pilot plant and industry solution for getting high purity IPA (99.9 % vol.) as final product. Our solution is basis at innovation technology cyclic catalytic (reactive) distillation column. As result you will get a completely new, highly effective technology and your company can take a leading position in the IPA market. Our service included pilot plant testing, design, equipment, installation, construction service, start-up, post-guaranty service.

ANALYSIS AND DESIGN OF DISTILLATION TRAYS FOR CYCLIC MASS TRANSFER

DISTILLATION TRAYS

Conditions of realization cyclic mass transfer expressed two postulates: lack of outflow of liquids to the trays vapor admission; lack of mixing of liquids in adjacent trays upon outflow of liquid. This method of interaction phases increase in efficiency mass transfer as compared to the standard process.

The method interaction phases in the distillation column can be as follows: discrete feed of liquid and vapor; continuous supply of liquid and discrete steam; constant supply of fluid and continuous steam. These conditions can be achieved at both the distillation column and the level distillation trays.

First stage of development of column internals for cyclic mass transfer was by external mechanical drives that are associated with elements of thrust trays. Pilot scale development and research of this solution has led to the establishment of individual actuators on each tray. In this case we have alternately devastation (overflow) distillation trays from bottom to top of distillation column, by changing the free sectional trays. Unfortunately, this method has not received industrial implementation.

In the second stage of development for liquid overflow on the distillation tray began to use the kinetic energy of motion of vapor in the distillation column.

In case of cyclic steam flow, the steam flow acts as a control of liquid flows in the distillation column. The main element of such distillation trays are sluice chambers and valves. In this case, the liquid flow (feed, reflux, distillate and bottom product) moves in a continuous mode. Cyclic mass transfer operation consisting of two key parts: vapor flows goes through the distillation column and the stationary liquid stays on the trays, and this is called the vapor flow period, while the liquid flow period arises when vapor flow is stopped and the liquid holdup in sluice chambers, the vapor flow period starts and liquid from sluice chambers falls into the tray below. The design of Maleta distillation trays and two key parts of interactions you can see at the picture. Today, Maleta distillation trays works in stripping column, rectification column and tray dividing wall columns with a diameter ranging from 400 to 1700 mm.

All of the methods and design of a cyclic mass transfer operation has its advantages and disadvantages and can be used in industrial process, depending on the tasks for increasing mass transfer efficiency in distillation column.