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.