Join Koch Modular at the 14^th annual AIChE Southwest Process Technology Conference in Houston, Texas, September 29-30, 2022 as our industry experts share their expertise on separation technology and applications within the chemical processing industry. 

At this year’s convention, Koch Modular Vice President, Alan Erickson, will discuss the benefits of the separation process known as extractive distillation––a powerful technique to separate close-boiling and azeotropic mixtures on Thursday, September 29th, 2022 at 2:00 pm CST.

“Our broad team of engineers take pride in seeking out and addressing the toughest separations problems for mass and heat transfer unit operations. The AIChE Southwest Process Technology conference is the ideal stage for us to showcase our unique knowledge and approach to extractive distillation to the world’s fastest-growing science markets,” said Erickson.

Our experienced engineers are ready to discuss the challenges associated with designing complex separation processes for optimal product recovery and purification.

Read the full press release HERE.

Chat with Alan

Alan Erickson is vice president of Koch Modular and has over 40 years experience designing separation processes and mass transfer equipment, with a special emphasis on distillation, extraction, extractive distillation, and solvent drying. He is a registered Professional Engineer and holds a B.S. degree from Rutgers University.

Email: alan.erickson@kochmodular.com

Direct: 201-267-8974 

Mobile: 201-394-2179

The post Koch Modular to Discuss Utilizing Extractive Distillation to Break Azeotropes at AIChE Southwest Process Technology Conference appeared first on Koch Modular Process System.

The Complexity of Breaking and Recognizing Azeotropes

To further complicate the situation, breaking or even recognizing when azeotropes are present is not always straightforward. It requires a comprehensive analysis of literature data, which frighteningly often does not exist. When no data is available, the next step is experimentation and subsequent analysis. Therefore, turning to companies with expertise in mass transfer and separations is critical.

It takes a substantial amount of experience to develop and conceptualize the proper approach to this type of experimentation and analysis. Recently, Chemical Processing published an e-book on distillation showcasing this level of expertise. It includes several case studies detailed inside.

The Importance of Pilot Testing

Very often, pilot plant testing is required to test the actual feedstock and show that the conceptual design first offered will meet the required specifications.

We love when drums of the actual feedstock that customers use are sent to us, so we can search for hidden, minute amounts of contaminants, often invisible at first (more ghoulish language)!

The differences between an ideal feedstock upon which the concept design was developed and the real feedstock make-up can affect the path chosen to break the azeotrope, but pilot testing uncovers those trace components and finds solutions.

Breaking Azeotropes: Homogeneous and Heterogeneous

Azeotropic distillation experts talk about heterogeneous azeotropes (the simplest ones to break) and homogeneous when two substances are totally miscible. When the two substances are homogeneous, such as acetonitrile and water, or THF and water, pressure swing distillation can be used; two distillation columns at different pressures will break the azeotrope.

On the other hand, when two substances are heterogeneous azeotropes (substances non miscible), a liquid separation agent is often used to form a ternary azeotrope, which then aids in the distillation process. Two examples of heterogeneous azeotropes are n-butanol and water or methylene chloride and water. Keep an eye out for those azeotropes.

Distillation Columns in Non-Ideal Seperations

Working with non-ideal separations, such as azeotropes, may require multiple distillation columns, and several decades of chemical process design experience. If you are suspicious that an azeotrope might be lurking in your process, chat up with one of our representatives at kochmodular.com. No ghosts there; it is manned by real, live chemical engineers!

The post Is Your Process Possessed by An Azeotrope? appeared first on Koch Modular Process System.

Are Toll Processors for Solvent Recovery Effective?

Currently, many manufacturers rely on toll processors to perform recovery of solvents. In addition to the transportation hazards, the toll processor may deal with a number of different materials for different customers. The residue that remains in the equipment could cause cross-contamination.

Other solutions for disposal such as incineration may be less attractive from an environmental standpoint.

There is also an economic downside. Resorting to disposal of used solvents and repurchase of virgin solvents is an expensive process, and many pharmaceutical companies are leaving significant amounts of money on the table.

Koch Modular Process Systems: A Proven Track Record In Solvent Recycling Solutions

The return on investment (ROI) for designing and installing an on-site solvent recovery unit can show remarkable results.

Case History According to Tom Schafer, Vice President at Koch Modular Process Systems, the payback period for installing a solvent recovery system can be less than two years.

“We built a THF (Tetrahydrofuran) Recovery System for a well-known pharmaceutical company. This system was fed a waste solvent stream that contained water, THF, Dichloromethane, toluene and some salts. There were several azeotropes present, and we needed four small distillation columns to recover the dry THF product.”

Schafer went on to explain that the recovered product purity was greater than 99.9 wt% THF. The system recovered 94.1% of the THF that was in the feed.

“The cost of the system installed was $3.8 MM”, said Schafer. “The annual savings from the recovered solvent was $2.2 MM. The operating cost for the system was $200,000 per year in utilities and manpower. The system paid for itself in less than two years.”

Koch Modular Solvent Recovery Options

Koch Modular solvent recovery units are available as modules, which are typically situated outdoors and have a 12’ by 12’ footprint. These modules can be manufactured inside, off-site and are ready for installation along a much more expedited timeline than traditional stickbuilt projects, often in remote locations.

Timelines are expedited and include an engineering study that provides the anticipated results and purity of recovered solvent, which Koch Modular provides in a Process Performance Guarantee.

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