Feasible designs hybrid processes

In seeking the most efficient process possible, a designer will wish to explore a wide range of feasible designs. To make this possible, an efficient method for the synthesis and assessment of any hybrid separation process has been developed. Since both processes have been analyzed using similar mathematical backgrounds, it is possible to use residue curve maps and column profile maps for both distillation and membranes to design hybrid systems of the two. 

The second stage is the proof of principle In this phase, we take the initial theoretical library idea and begin to apply chemistry experiments to validate experimental designs and potential library schemes at this stage, one also evaluates the method of library production (solid/solution/hybrid phases). In this phase, which is usually the longest phase in any library production process, we will perform the initial experiments, optimize the chemical yields and purities, modify the experiments to generate easily removable by-products, which can be removed by traditional parallel purification methods (i.e. SPE, Resin capture), and determine the most feasible route to the final product. 

A cost effective design for a bio-ethanol separation plant using conceptual design followed by rigorous simulation is found. The minimum in the operation costs corresponds to a minimum in the steam flow rate of the hybrid column (1600 kg/h). The minimum in steam flow rate can be only explained by the presence of the fusel component, which influences both the energy demand and feasible products of the process. Therefore, designs based on the binary system ethanol-water do not represent the system behaviour in an accurate way. 

Knowledge of the equilibrium is a fundamental prerequisite for the design of non-reactive as well as reactive distillation processes. However, the equilibrium in reactive distillation systems is more complex since the chemical equilibrium is superimposed on the vapor-liquid equilibrium. Surprisingly, the combination of reaction and distillation might lead to the formation of reactive azeotropes. This phenomenon has been described theoretically [2] and experimentally [3] and adds new considerations to feasibility analysis in RD [4]. Such reactive azeotropes cause the same difficulties and limitations in reactive distillation as azeotropes do in conventional distillation. On the basis of thermodynamic methods it is well known that feasibility should be assessed at the limit of established physical and chemical equilibrium. Unfortunately, we mostly deal with systems in the kinetic regime caused by finite reaction rates, mass transfer limitations and/or slow side-reactions. This might lead to different column structures depending on the severity of the kinetic limitations [5], However, feasibility studies should identify new column sequences, for example fully reactive columns, non-reactive columns, and/or hybrid columns, that deserve more detailed evaluation. 

The concept is therefore straightforward the two membrane/PSA processes complement each other by removing diflerent components from the mixture. While adsorption removes impurities from the H2 product, the membrane takes H2 from the impurities that are retained as residue. Either because of the operational complexity of this type of integrated processes, either due to the mathematical complexity involved in the design procedures, research on feasible hybrid systems is still scarce. 

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