Optimization of the Process of Batch Distillation of Binary Mixtures
Optimization of the Process of Batch Distillation of Binary Mixtures
com
Adnan Hadžihasanović et al, Cognizance Journal of Multidisciplinary Studies, Vol.4, Issue.12, December 2024, pg. 381-394
(An Open Accessible, Multidisciplinary, Fully Refereed and Peer Reviewed Journal)
ISSN: 0976-7797
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DOI: 10.47760/cognizance.2024.v04i12.036
Abstract: The method of dynamic optimization, known as maximum principle of Pontryagin, is presented. It
is applied to the process of batch rectification of binary mixtures, with aim of solving the problem of
minimum time (for given distillate quantity of specified composition) or maximum distillate quantity of
specified composition (for given batch time). The optimum profiles of reflux ratio are found for seven
different separation tasks, based on semi-rigorous model without holdups. The results obtained for distillate
quantity are compared to respective results obtained with constant reflux ratio and constant distillate
composition working policies, and also with the results of other authors. The solution algorithms for all the
three working policies are given. Computer implementation of the algorithms is performed in programming
language FORTRAN.
Keywords: Batch distillation, Mathematical modeling, Dynamic optimization, Maximum principle of Pontryagin.
I. INTRODUCTION
The optimization of batch distillation processes, particularly for binary mixtures, is a critical area of study in
chemical engineering, aiming to enhance efficiency and output quality. Batch distillation, unlike continuous
distillation, operates over a series of discrete steps, making it ideal for the production of high-purity specialty
chemicals in smaller quantities. The process involves heating a mixture until one component vaporizes more
than the other, then condensing the vapor to separate it from the mixture. The challenge lies in determining the
optimal conditions—such as the reflux ratio, heating rates, and the number of stages—for the separation to be
most effective. Advanced mathematical models and simulations have been developed to predict the behavior of
these systems, incorporating factors like relative volatility and mass balance. These models are essential for
industries that require rapid and robust methods for separating volatile organic compounds, as environmental
regulations become increasingly stringent. Researchers have employed various methodologies, including the
Fenske-Underwood-Gilliland (FUG) equations and sensitivity analysis, to design and optimize batch distillation
columns. Experimental validation of these models ensures their reliability and applicability in real-world
scenarios. The ultimate goal of this optimization is to achieve the desired degree of separation while minimizing
energy consumption and maximizing production efficiency. As computational power increases, so does the
ability to solve complex optimization problems, leading to more sophisticated and efficient batch distillation
operations. The continuous evolution of optimization techniques in batch distillation reflects the dynamic nature
of the chemical industry and its adaptation to market demands and environmental considerations.
The semi-rigorous model of multicomponent batch distillation [1] is based on the following assumptions:
relative volatilities are constant, molar holdups of the plates and of the condenser are neglected, vapor flowrate
is constant, heat balance is neglected. The model is composed of the total material balance and the component
material balance:
(1)
(2)
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Adnan Hadžihasanović et al, Cognizance Journal of Multidisciplinary Studies, Vol.4, Issue.12, December 2024, pg. 381-394
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ISSN: 0976-7797
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where: MN+1 is the holdup of the reboiler, t is the time, V is the vapor flowrate, R is the reflux ratio, xi,N+1 is the
fraction of the i-th component in the liquid phase in the reboiler, xi,0 is the fraction of the i-th component in the
liquid phase in the condenser.
The current composition of the liquid in the condenser is obtained by solving the following system of nonlinear
equations:
(3)
∑
where: yi,n is the fraction of the i-th component in the vapor phase on the n-th plate, Ki,n is the equilibrium ratio
of evaporation of the i-th component on the n-th plate, xi,n is the fraction of the i-th component in the liquid
phase on the n-th plate, xi,n-1 is the fraction of the i-th component in the liquid phase on the plate above the n-th
plate.
This model can be solved relatively easily in the case of a binary mixture. The equations for the calculation
plate-by-plate down the column are [2]:
( ) (4)
(5)
where: xn is the fraction of the more volatile component in the liquid phase on the n-th plate, yn is the fraction of
the more volatile component in the vapor phase on the n-th plate, α is the relative volatility of the more volatile
component, yn+1 is the fraction of the more volatile component in the vapor phase on the plate below the n-th
plate, y1 is the fraction of the more volatile component in the vapor phase on the first plate.
In this case, the fact that the plate-by-plate calculation must arrive at a given value of the composition in the
reboiler, xN+1, means that y1 must be assumed and then solved iteratively.
The following operating modes of batch distillation are known: (1) mode with a constant reflux ratio, (2)
mode with a constant distillate composition, and (3) mode with an optimal reflux ratio profile. The mode with a
constant reflux ratio is most often applied in practice, because its control is the simplest. However, at a constant
reflux ratio, the mole fraction of the more volatile component in the distillate decreases with time. Therefore, it
is necessary to find such a reflux ratio at which the average composition of the collected distillate will be equal
to the desired value. The mode with a constant distillate composition is less often applied in practice. This mode
of operation requires an expensive composition sensor and its control is more complicated. In order to maintain
the composition of the distillate at the desired value, it is necessary to continuously increase the reflux ratio,
because the liquid in the reboiler is depleted of more volatile component as the process progresses. The mode
with an optimal profile of the reflux ratio, in addition to achieving the desired composition of the distillate, also
aims to obtain its maximum amount in the given time of the process [3], [4], [5], [6] or the minimum duration of
the process for a given amount of distillate [2], [7], [8], [9], [10], [11]. This reflux ratio profile will generally lie
between the profiles of the previous two operating modes. Also, by combining the minimum time and maximum
distillate amount problems, a reflux ratio profile that maximizes profit can be found [12].
Converse and Gross solved the maximum distillate amount problem using dynamic programming [13], the
calculus of variations [14], and the maximum principle [15]. Murty et al. solved this problem using dynamic
programming [13], the maximum principle [15], the quasilinearization technique [16], the method of conjugate
gradients [17] and the method of sequential conjugate gradients [18]. Divekar et al. solved the problem using the
maximum principle [15], and Logsdon and Biegler using nonlinear programming [19], [20], [21], [22]. The
minimum time problem was solved by Coward, Robinson, Mayur and Jackson, and Hansen and Jorgensen using
the maximum principle [15].
We consider in this paper the problem of maximum distillate quantity of specified composition for given
batch time. The optimum profiles of reflux ratio are found for seven different separation tasks, based on semi-
©2024, Cognizance Journal, ZAIN Publications, Fridhemsgatan 62, 112 46, Stockholm, Sweden, All Rights Reserved 382
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Adnan Hadžihasanović et al, Cognizance Journal of Multidisciplinary Studies, Vol.4, Issue.12, December 2024, pg. 381-394
(An Open Accessible, Multidisciplinary, Fully Refereed and Peer Reviewed Journal)
ISSN: 0976-7797
Impact Factor: 4.843
Index Copernicus Value (ICV) = 77.57
rigorous model without holdups. The results obtained for distillate quantity are compared to respective results
obtained with constant reflux ratio and constant distillate composition working policies, and also with the results
of other authors [4]. We show that with optimal reflux ration mode we can achieve maximum distillate quantity.
( )
∑ (9)
( ) ∑ ( ) (10)
(11)
(12)
According to Pontryagin's maximum principle, the Hamiltonian function reaches its maximum value at the
point u = u(t), where u is the value of the control parameter along the optimal path. In addition, the Hamiltonian
function is positive and constant in the time range t0 ≤ t ≤ t1. Applying these equations to batch distillation
allows solving the problem of optimal time or optimal amount of distillate (minimum time or maximum amount
of distillate). For binary batch distillation without holdup, the basic system of differential equations, which
corresponds to equation (6), is:
(13)
(14)
These equations make it possible to define the Hamiltonian function according to equation (10), as [7]
(15)
where two additional variables p1 and p2 can be defined according to equations (9) or (12) as [7]
(16)
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Adnan Hadžihasanović et al, Cognizance Journal of Multidisciplinary Studies, Vol.4, Issue.12, December 2024, pg. 381-394
(An Open Accessible, Multidisciplinary, Fully Refereed and Peer Reviewed Journal)
ISSN: 0976-7797
Impact Factor: 4.843
Index Copernicus Value (ICV) = 77.57
(17)
step 1
( ) ( )
step 2
( )
step 3
( )
( )
( )
( )
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Adnan Hadžihasanović et al, Cognizance Journal of Multidisciplinary Studies, Vol.4, Issue.12, December 2024, pg. 381-394
(An Open Accessible, Multidisciplinary, Fully Refereed and Peer Reviewed Journal)
ISSN: 0976-7797
Impact Factor: 4.843
Index Copernicus Value (ICV) = 77.57
( ) ( ) ( )
( ) ( )
| | ( )
( ) ( )
( )
( ) ( )
( )
( ) ( ) ( ) ( )
( )
̅ ( ) ( )
( )
| ̅ | (if not go to step 1)
( )
step 1
( )
( ) ( )
step 2
( )
( )
( )
( )
( )
( )
( ) ( ) ( )
( ) ( )
( ) ( )
| | ( )
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Adnan Hadžihasanović et al, Cognizance Journal of Multidisciplinary Studies, Vol.4, Issue.12, December 2024, pg. 381-394
(An Open Accessible, Multidisciplinary, Fully Refereed and Peer Reviewed Journal)
ISSN: 0976-7797
Impact Factor: 4.843
Index Copernicus Value (ICV) = 77.57
( ) ( )
( )
( ) ( )
( )
step 1
( )
step 2
( )
step 3
( )
step 4
( )
( )
( )
( )
( )
( ) ( ) ( )
( ) ( )
( ) ( )
| | ( )
( ) ( )
( ) ( ) ( )
( ) ( ) ( )
( )
( ) ( ) ( )
( )
©2024, Cognizance Journal, ZAIN Publications, Fridhemsgatan 62, 112 46, Stockholm, Sweden, All Rights Reserved 386
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Adnan Hadžihasanović et al, Cognizance Journal of Multidisciplinary Studies, Vol.4, Issue.12, December 2024, pg. 381-394
(An Open Accessible, Multidisciplinary, Fully Refereed and Peer Reviewed Journal)
ISSN: 0976-7797
Impact Factor: 4.843
Index Copernicus Value (ICV) = 77.57
( ) ( )
( )
step 5
( )
( )
( )
( )
( )
( ) ( ) ( )
( ) ( )
( ) ( )
| | ( )
( ) ( )
( )
( ) ( )
( )
( )
( ) ( )
( ) ( )
( )
step 6
( )
( )
( )
( )
( )
( ) ( ) ( )
( ) ( )
( ) ( )
| | ( )
( )
( )
( )
( ) ( )
©2024, Cognizance Journal, ZAIN Publications, Fridhemsgatan 62, 112 46, Stockholm, Sweden, All Rights Reserved 387
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Adnan Hadžihasanović et al, Cognizance Journal of Multidisciplinary Studies, Vol.4, Issue.12, December 2024, pg. 381-394
(An Open Accessible, Multidisciplinary, Fully Refereed and Peer Reviewed Journal)
ISSN: 0976-7797
Impact Factor: 4.843
Index Copernicus Value (ICV) = 77.57
( )
( ) ( ) ( ) ( )
( )
̅ ( ) ( )
( )
| ̅ | ( )
IV. CONCLUSION
By analyzing the obtained results, the following conclusions can be drawn:
• The amount of distillate obtained is the highest at the operating mode with the optimal reflux ratio
profile, for the same initial conditions and the same restriction on the distillate composition;
• The results obtained using the semi-rigorous model are in good agreement with the corresponding
results of other authors, who used the same model;
• The maximum values of the Hamiltonian function at the optimal reflux ratio are uniform and positive,
which is in agreement with Pontryagin's maximum principle;
• With a semi-rigorous process model, which does not take into account either the holdup of the reflux
accumulator or that of the column plates, objective results of the dynamic optimization of batch distillation can
be obtained;
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Adnan Hadžihasanović et al, Cognizance Journal of Multidisciplinary Studies, Vol.4, Issue.12, December 2024, pg. 381-394
(An Open Accessible, Multidisciplinary, Fully Refereed and Peer Reviewed Journal)
ISSN: 0976-7797
Impact Factor: 4.843
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• Dynamic optimization of batch distillation, based on the maximum principle of Pontryagin, finds the
optimal solution even when other modes of operation give a result that is close to optimal;
• The use of the semi-rigorous model is limited to ideal systems and to the initial design of the column,
or to finding the initial operating conditions;
• The obtained results must be verified using a rigorous dynamic column model, accurate physical
properties of the mixture and rigorous integration methods.
REFERENCES
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no. 7, pp. 961-970, 1978/01/01/ 1978.
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applied mathematics; v. 55). Oxford: Pergamon Press; [distributed in the Western Hemisphere by Macmillan, New York], 1964.
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APPENDIX
TABLE I.
INPUT DATA**
Case no. M(0)N+1, mol x(0)N+1, mol/mol x0*, mol/mol
1 116.1 0.715 0.950
2 74.3 0.420 0.900
3 116.1 0.580 0.930
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Adnan Hadžihasanović et al, Cognizance Journal of Multidisciplinary Studies, Vol.4, Issue.12, December 2024, pg. 381-394
(An Open Accessible, Multidisciplinary, Fully Refereed and Peer Reviewed Journal)
ISSN: 0976-7797
Impact Factor: 4.843
Index Copernicus Value (ICV) = 77.57
TABLE II.
AMOUNT OF OBTAINED DISTILLATE AT DIFFERENT OPERATING MODES
Amount of distillate of required purity, mol
TABLE III.
COMPARATIVE RESULTS
Amount of distillate of required purity, mol
Case no. Murty et al. This paper
1 25.979 26.131
2 6.082 6.136
3 16.397 16.380
4 4.379 4.106
5 22.827 22.963
6 38.752 37.985
7 46.204 51.411
TABLE IV.
VALUES OF P2(0) THAT SATISFY CONSTRAINT ON DISTILLATE PURITY
Case no. p2(0)
1 -547.99
2 -157.15
3 -351.41
4 -264.824
5 -340.15
6 -695.76
7 -1213.75
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(An Open Accessible, Multidisciplinary, Fully Refereed and Peer Reviewed Journal)
ISSN: 0976-7797
Impact Factor: 4.843
Index Copernicus Value (ICV) = 77.57
TABLE V.
MAXIMUM VALUES OF HAMILTONIAN FUNCTION AT OPTIMAL REFLUX RATIO
Hmax
Case
no. t = 0.0 h t = 0.5 h t = 1.0 h
5.0
(a)
4.0
Reflux ratio
(b)
(c)
3.0
2.0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Time, h
Fig. 1 Reflux ratio as a function of time for different operating modes:
(a) constant composition, (b) optimal reflux ratio and (c) constant reflux ratio.
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0.958
0.957 (c)
0.956
Current distillate composition, mol/mol
0.955 (b)
0.954
0.953
0.952
0.951
(a)
0.950
0.949
0.948
0.947
0.946
0.945
0.944
0.943
0.942
0.941
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Time, h
Fig 2. Current distillate composition as a function of time for different operating modes:
(a) constant composition, (b) optimal reflux ratio and (c) constant reflux ratio.
3.7
3.4
Hamiltonian
3.3
3.2
3.1
3.0
2.9
2.8
2.0 2.5 3.0 3.5 4.0
Reflux ratio
Fig 3. Hamiltonian as a function of reflux ratio for
initial conditions and different values of p2(0) and p1(0) = 1.
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-450 1.4
-475 1.3
P2
P1
-500 1.2
-525 1.1
-550 1.0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Time, h
4.0
(a)
3.5
(b)
Hamiltonian
3.0
(c)
2.5
2.0
2.0 2.5 3.0 3.5 4.0
Reflux ratio
Fig 5. Hamiltonian as a function of reflux ratio at: (a) t = 0.0 h, (b) t = 0.5 h and (c) t = 1.0 h.
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(An Open Accessible, Multidisciplinary, Fully Refereed and Peer Reviewed Journal)
ISSN: 0976-7797
Impact Factor: 4.843
Index Copernicus Value (ICV) = 77.57
NOMENCLATURE
H Hamiltonian function
K equilibrium ratio of evaporation
M holdup, mol
N number of plates in column
NC number of components in mixture
p additional variable
R reflux ratio
t current time, h
T total time, h
V vapor flowrate, mol/h
x fraction of component in liquid phase, mol/mol
y fraction of component in vapor phase, mol/mol
Greek letters
α relative volatility
ε accuracy
Indexes
i counter of component in mixture (i = 1, ..., C; i = 1, ..., NC)
j counter of plate in column (j = 0, ..., N+1; 0 – condenser, N+1 – reboiler)
n counter of plate in column (n = 0, ..., N+1; 0 – condenser, N+1 – reboiler)
Exponents
j counter of reflux ratio in k-th step of time
J total number of reflux ratios
k counter of step in time
K total number of steps in time
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