Nous étudions la faisabilité du procédé de distillation extractive continue pour séparer des mélanges azéotropiques A-B à température de bulle minimale ou maximale, avec un tiers corps E lourd ou léger. Les mélanges ternaires A-B-E appartiennent aux classes 1.0-1-a et 1.0-2 qui se subdivisent chacune en deux souscas selon la position de la courbe d'univolatilité. La colonne de distillation a trois sections, rectification, extractive, épuisement. Nous établissons les équations décrivant les profiles de composition liquide dans chaque section en fonction des paramètres opératoires: pureté et taux de récupération du distillat, taux de reflux ratio R et rapport des débits d'alimentation FE/F dans le cas d'un tiers corps lourd ; pureté et taux de récupération du produit de pied, taux de rebouillage S et rapport des débits d'alimentation FE/F dans le cas d'un tiers corps léger. Avec un tiers corps lourd alimenté comme liquide bouillant au dessus de l'étage d'alimentation du mélange A-B, nous identifions le distillat atteignable et les plages de valeurs faisables des paramètres R et FE/F à partir du critère général de faisabilité énoncé par Rodriguez-Donis et al. (Ind. Eng. Chem. Res, 2009, 48(7), 3544–3559). Pour la classe 1.0-1a, il existe des rapport FE/F et reflux ratio minimum. Le rapport FE/F est plus important pour le procédé continu que pour le procédé discontinu parce que la faisabilité du procédé continu nécessite que les profils d'épuisement et extractifs s'intersectent. Pour la classe 1.0-2, les deux constituants A et B sont des distillats potentiels, l'un sous réserve que le rapport FE/F reste inférieur à une valeur limite maximale. Le procédé continu exhibe également une valeur minimale de FE/F à un taux de reflux ratio donné, contrairement au procédé discontinu. Avec un tiers corps léger alimenté comme vapeur saturante sous l'étage d'alimentation du mélange A-B, nous identifions le produit de pied atteignable et les plages de valeurs faisables des paramètres S et FE/F à partir du critère général de faisabilité énoncé par Rodriguez-Donis et al. (Ind. Eng. Chem. Res, 2012, 51, 4643–4660). Comparé au cas des tiers corps lourds, le produit principal est obtenu en pied. Autrement, les comportements des classes 1.0-1a et 1.0-2 sont analogues entre les tiers corps léger et lourd. Avec un tiers corps léger, le procédé continu ajoute la contrainte que les profils de rectification et extractifs s'intersectent. La contrainte d'intersection des profils d'épuisement et extractif est partagée par les deux modes opératoires continu et discontinu. Ce travail valide la méthodologie proposée pour évaluer la faisabilité du procédé de distillation extractive continue et permet de comparer les tiers entre eux en termes de taux de reflux ratio minimum et de rapport de débit d'alimentation minimal / We study the continuous extractive distillation of minimum and maximum boiling azeotropic mixtures A-B with a heavy or a light entrainer E, intending to assess its feasibility based on thermodynamic insights. The ternary mixtures belong to the common 1.0-1a and 1.0-2 class ternary diagrams, each with two sub-cases depending on the univolatility line location. The column has three sections, rectifying, extractive and stripping. Differential equations are derived for each section composition, depending on operating parameters: distillate product purity and recovery, reflux ratio R and entrainer – feed flow rate ratio FE/F for the heavy case; bottom product purity and recovery, reboil ratio and entrainer – feed flow rate ratio for the light entrainer case. For the case with a heavy entrainer fed as a boiling liquid above the main feed, the feasible product and operating parameters R and FE/F ranges are assessed under infinite reflux ratio conditions by using the general feasibility criterion enounced by Rodriguez-Donis et al. (Ind. Eng. Chem. Res, 2009, 48(7), 3544–3559). For the 1.0-1a class, there exists a minimum entrainer - feed flow rate ratio to recover the product, and also a minimum reflux ratio. The minimum entrainer - feed flow rate ratio is higher for the continuous process than for the batch because of the additional requirement in continuous mode that the stripping profile intersects with the extractive profile. For the 1.0-2 class both A and B can be distillated. For one of them there exists a maximum entrainer - feed flow rate ratio. The continuous process also has a minimum entrainer - feed flow rate ratio limit for a given feasible reflux ratio. For the case with a light entrainer fed as saturated vapor below the main feed, the feasible product and operating parameters S and FE/F ranges are assessed under infinite reflux ratio conditions by using the general feasibility criterion enounced by Rodriguez-Donis et al. (Ind. Eng. Chem. Res, 2012, 51, 4643–4660), Compared to the heavy entrainer case, the main product is removed from the column bottom. Similar results are obtained for the 1.0-1a and 1.0-2 class mixtures whether the entrainer is light or heavy. With a light entrainer, the batch insight about the process feasibility holds for the stripping and extractive sections. Now, an additional constraint in continuous mode comes from the necessary intersection between the rectifying and the extractive sections. This work validates the proposed methodology for assessing the feasibility of continuous extractive distillation processes and enables to compare entrainers in terms of minimum reflux ratio and minimum entrainer feed flow rate ratio

Thesis (MScEng)--Stellenbosch University, 2012. / ENGLISH ABSTRACT: Distillation is the most widely used separation technique in the chemical process industry and typically accounts for approximately one-third of the total capital cost and more than half of the total energy consumption of a typical petrochemical-chemical plant. Therefore, the design and optimization of the distillation sequence are of critical importance to the economics of the entire process. Azeotropic mixtures cannot be separated into their pure components via normal distillation. Enhanced distillation techniques such as heterogeneous azeotropic distillation should be considered for these mixtures. Isobaric vapour-liquid-liquid equilibrium (VLLE) data are highly important for the design and analysis of heterogeneous distillation columns. However, limited VLLE data are available in literature due to the difficulties involved with measuring such data. The objective of this work was to systematically evaluate and compare the performance of selected entrainers (including benzene, DIPE and cyclohexane) for the dehydration of C2 and C3 alcohols. To meet this objective, phase equilibrium data had to be measured. Isobaric VLLE at standard atmospheric conditions were measured with a dynamic Guillespie unit equipped with an ultrasonic homogenizer, which prevented liquid-liquid separation. Vapour-liquid equilibrium (VLE) and VLLE data were measured for ethanol/water/di-isopropyl ether (DIPE), n-propanol/water/DIPE and n-propanol/water/isooctane. The VLE data were found to be thermodynamically consistent according to the L-W (Wisniak 1993) and McDermott-Ellis consistency tests. No thermodynamic consistency test, specifically for VLLE data, could be found in literature, but the LLE part of the data followed a regular profile according to the Othmer-Tobias correlation. The binary DIPE/water and isooctane/water azeotropes, as well as ternary ethanol/DIPE/water and n-propanol/isooctane/water azeotropes, as measured in this work, agree well with those found in literature. Regressed parameters for the NRTL, UNIQUAC, and UNIFAC models, generally improved the model predictions compared with built-in Aspen parameters. This confirmed the importance of having actual measured VLLE data available for evaluation and improvement of estimations by thermodynamic models. NRTL predicted the ethanol/DIPE/water and n-propanol/DIPE/water VLLE most accurately. Despite the improved regressed parameters for n-propanol/isooctane/water predictions, the models are still considered unsuitable for accurate prediction of the VLLE behaviour of this system. Separation sequences were simulated in Aspen with built-in and regressed parameters, respectively, to illustrate the significant effect such inaccurate parameters have on these simulations. Phase diagram (VLLE data) evaluation of ethanol and isopropanol (IPA) with various entrainers, as found in literature, indicated that DIPE might be a good entrainer for the dehydration of these alcohols. Benzene and cyclohexane are generally used as entrainers in industry for these processes. Benzene is however carcinogenic and therefore an alternative has to be found (United States Department of Labour - Occupational Safety & Health Administration 2011). Separation sequences were simulated for ethanol dehydration with benzene and DIPE as entrainers, respectively. Taking cost and safety into account, DIPE can be considered an acceptable replacement for benzene as entrainer for ethanol dehydration. A separation sequence was also simulated for the dehydration of IPA with DIPE as entrainer and compared to a simulation with cyclohexane (Arifin, Chien 2007) as entrainer. DIPE was found to be a reasonable alternative to cyclohexane as entrainer for IPA dehydration. Two other separation sequences were simulated as practical examples where DIPE could be used as entrainer for the recovery of ethanol or n-propanol from aqueous Fischer Tropsch waste streams. DIPE is therefore found to be a feasible alternative entrainer to benzene and cyclohexane for the dehydration of ethanol and IPA via heterogeneous azeotropic distillation, based on pre-liminary cost considerations, separation ability and safety. Better entrainers than DIPE may exist, but from the data available in literature and the measurements made in this work DIPE appears to be superior to benzene, cyclohexane and isooctane. / AFRIKAANSE OPSOMMING: Distillasie is die mees algemeen-gebruikte skeidingstegniek in die chemiese proses-industrie. Dit is tipies verantwoordelik vir ʼn derde van die totale kapitaalkoste en meer as die helfte van die totale energie verbruik op ʼn tipiese petrochemiese chemiese aanleg. Daarom is die ontwerp en optimering van ʼn distillasie trein van kardinale belang vir die winsgewendheid van die proses. Azeotropiese mengsels kan nie slegs deur normale distillasie in suiwer komponente geskei word nie. Gevorderde distillasie tegnieke soos heterogene azeotropiese distillasie moet dus oorweeg word vir sulke mengsels. Isobariese damp-vloeistof-vloeistof ewewigsdata is een van die belangrikste fisiese eienskappe vir die ontwerp van heterogene distillasie kolomme. Die hoeveelheid damp-vloeistof-vloeistof ewewigsdata wat beskikbaar is in die literatuur is egter baie beperk omdat dit moeilik is om die data te meet. In hierdie werk is isobariese damp-vloeistof-vloeistof ewewigsdata met ʼn dinamiese Guillespie eenheid, by standaard atmosferiese druk gemeet. Die eenheid is toegerus met ʼn ultrasoniese homogeniseerder om vloeistof-vloeistof skeiding te voorkom. Temperatuur is gemeet met ʼn akkuraatheid van 0.03oC by 0oC. Die sisteem se druk is konstant gehou op 101.3 kPa met ʼn akkuraatheid van 0.35 % VSU (Vol Skaal Uitset). Die ewewigsamestellings is met ʼn relatiewe akkuraatheid van 2 % gemeet. Daar is damp-vloeistof en damp-vloeistof-vloeistof ewewigsdata van etanol/water/di-isopropiel eter (DIPE), npropanol/ water/ DIPE en n-propanol/water/iso-oktaan gemeet. Die damp-vloeistof ewewigsdata is deur die LW (Wisniak 1993) en McDermott-Ellis termodinamiese konsistensie toetse getoets en konsistent bevind. Geen termodinamiese konsistensie toets spesifiek vir damp-vloeistof-vloeistof ewewigsdata kon gevind word nie. Die Othmer-Tobias korrelasie dui egter aan dat die vloeistof-vloeistof ewewig gedeelte van die data ʼn reëlmatige gang volg. Die binêre DIPE/water en iso-oktaan/water azeotrope en ternêre etanol/DIPE/water en n-propanol/iso-oktaan/water fase-ewewigte wat in hierdie werk gemeet is, stem ooreen met die wat in die literatuur te vind is. Die parameters vir die modelle (NRTL, UNIQUAC en UNIFAC) wat in hierdie werk bestudeer is, is in die algemeen verbeter deur regressie van die eksperimentele data. Dit dui daarop dat dit belangrik is om eksperimentele damp-vloeistof-vloeistof ewewigsdata te hê om die voorspellings van termodinamiese modelle mee te evalueer en te verbeter. Die etanol/water/ DIPE en n-propanol/water/DIPE damp-vloeistof-vloeistof ewewigsdata is die akkuraatste deur NRTL voorspel. Ten spyte van die verbeteringe wat deur regressie behaal is met die NRTL en UNIQUAC parameters vir n-propanol/water/isooktaan, word hierdie modelle steeds nie as gepas vir die voorspelling van hierdie datastel beskou nie. Skeidingsreekse is gesimuleer met die ingeboude Aspen parameters en regressie parameters, onderskeidelik, om te illustreer dat onakkurate parameters ʼn beduidende effek op sulke simulasies het. Die evaluasie van fase diagramme van etanol en IPA met verskeie skeidingsagente, wat in die literatuur te vind is, dui aan dat DIPE ʼn goeie skeidingsagent kan wees vir die dehidrasie van hierdie alkohole. Skeidingsreekse vir die dehidrasie van etanol met benseen en DIPE, onderskeidelik, is gesimuleer. Met koste en veiligheid in ag geneem, is daar gevind dat DIPE ʼn aanvaarbare plaasvervanger vir benseen as skeidingsagent vir etanol dehidrasie kan wees. Daar is ook ʼn skeidingsreeks vir die dehidrasie van IPA met DIPE as skeidingsagent gesimuleer en met ʼn simulasie (Arifin, Chien 2007) wat sikloheksaan as skeidingsagent gebruik, vergelyk. Daar is bevind dat DIPE ʼn redelike alternatief vir sikloheksaan kan wees as skeidingsagent vir IPA dehidrasie. Nog twee skeidingsreekse is gesimuleer om as praktiese voorbeelde te dien van die gebruik van DIPE as skeidingsagent om etanol of n-propanol vanaf waterige Fischer-Tropsch afvalstrome te herwin. Daarom is daar bevind dat DIPE ʼn geldige alternatiewe skeidingsagent vir benseen en sikloheksaan is, gebaseer op koste, skeidingsvermoë en veiligheid. Daar kan beter skeidingsagente as DIPE bestaan, maar vanuit die data beskikbaar in literatuur en die metings geneem in hierdie werk, is DIPE die beste.

The most prevalent method for the prevention of freeze-thaw and salt scaling damage in cement based materials is through the entrainment of air voids using air entraining chemical admixtures (AEA's). However, the common field methods for measuring air content in fresh concrete cannot distinguish between entrained and entrapped air voids, and the actual air content in the hardened concrete can vary from that determined by these tests due to a variety of factors such as workability, placing operations, consolidation efforts, and environmental conditions. Previous research has shown the ability of ultrasonic attenuation to distinguish between entrained and entrapped air voids in hardened cement paste, providing a foundation for an inversion procedure to calculate the size and volume content of the two scatterer sizes. While additional challenges are present with measurements in fresh paste, the use of an immersion setup can overcome the limitations of cement paste containment vessels and provide a means to measure air content from batching to placement. An immersion apparatus to monitor ultrasonic wave attributes including attenuation in fresh cement paste is designed and built. Results comparing air entrained and non-air entrained cement pastes are presented. Ultrasonic wave attributes are studied as a function of time and level of chemical air entrainer. Finally, recommendations are made to improve the accuracy of the immersion apparatus in order to develop an in situ, quality control procedure to quantify the air content of fresh cement paste from batching to placement.