Project Synopsis
Perform an independent design review of a Distillation and Dehydration Unit process design package (PDP) developed by others.
Project Summary
The client is a US industrial biotechnology company that has developed a proprietary fermentation process to convert low-cost feedstocks into ethanol. The client plans to build a new plant in the far-east in joint venture cooperation with several international partners. The primary purpose of this project was to review and provide comments on the Distillation and Dehydration Unit process design package (PDP) previously developed by an international design institute for the client. The purpose of the Distillation and Dehydration Unit is to separate water and other impurities from the ethanol product stream. Process Engineering Associates, LLC (PROCESS) was contracted to perform an independent engineering design review.
Specific tasks for this project included:
- Evaluate Aspen Plus® simulations of the Distillation and Dehydration Unit by replicating in CHEMCAD. PROCESS also checked relative volatilities, recoveries, recycle streams, tray efficiencies, packing height equivalent to a theoretical plate (HETP), pressure drop, heat integration, etc.
- Analyze the feasibility of fusel oil removal at the proposed tower location and/or propose alternatives.
- Assess the consistency of the process design package documentation by comparing Design Basis, Process Description, Process Flow Diagrams, Heat and Material Balance, Piping and Instrumentation Diagrams, Equipment Layout, Equipment List and Specifications, Utility Summary, Battery Limit Conditions, Analytical List, Control Strategy, and Operating Procedures.
- Verify equipment sizing of distillation and dehydration columns, heat exchangers, pumps, and vapor/liquid separators.
- Complete a hydraulic analysis of the trayed column internals.
- Identify potential issues with process control strategy and with clean-in-place (CIP), molecular sieve regeneration, and startup/shutdown procedures.
The team identified over 100 items for follow-up including potential design issues, apparent gaps, and inconsistencies with varying levels of significance. The findings were summarized in a detailed report for the client to utilize in the next phase of process design.
Industry Type
Ethanol Production
Utilized Skills
- Independent process design review
- Distillation design evaluation.