Comprehensive evaluation and comparison of advanced separation methods on the separation of ethyl acetate-ethanol-water highly non-ideal mixture

Computational understanding of Na-LTA for ethanol-water separation

There is a growing demand for high purity ethanol as an electronic chemical. The conventional distillation process is effective for separating ethanol from water but consumes a significant amount of energy. Selective membrane separation using the LTA-type molecular sieve has been introduced as an alternative. The density functional theory simulation indicates that aluminum (Al) sites are evenly distributed throughout the framework, while sodium (Na+) ions are preferentially located in the six-membered ring. The movement of ethanol molecules can cause Na+ ions to be transported towards the eight-membered ring, hindering the passage of ethanol through the channel. In contrast, the energy barrier for water molecules passing through the channel occupied by Na+ ions is significantly lower, leading to a high level of selectivity for ethanol-water separation.

Antioxidant and antimicrobial characteristics of ethyl acetate polar fractions from walnut green husk

Walnut green husk (WGH) is rich in natural compounds and is valued as a potential source of antioxidant and antimicrobial properties. In this study, the antioxidant and antimicrobial activities of petroleum ether polar fraction, dichloromethane polar fraction, ethyl acetate polar fraction (EAPF), and n-butanol polar fraction from WGH were analyzed. The results showed that EAPF exhibited the highest total flavonoid content (65.74 ± 1.01 mg rutin equivalents [RE]/g dry weight [DW]) and total phenol content (48.73 ± 1.09 mg gallic acid equivalent [GAE]/g DW), with the highest 2,2-diphenyl-1-picrylhydrazyl, hydroxyl radical (•OH), and 2,2-azino-bis-3-ethylbenzothiazoline-6-sulfonate scavenging activity compared with other fractions. EAPF also showed good antibacterial activity against Escherichia coli and Bacillus cereus vegetative cells, with a diameter of inhibition zones of 33.5 and 37.6 mm, respectively, a minimum inhibitory concentration of 31.25 mg/ml and a minimum bactericidal concentration of 62.5 mg/ml, which inhibited the growth of both bacteria. Analysis of the antibacterial mechanism demonstrated that EAPF damaged the integrity of the cell membrane, increased the membrane permeability, and triggered the leakage of intracellular material. In addition, ultrahigh performance liquid chromatography-tandem with mass spectrometry analysis revealed that 8 polyphenols and 14 flavonoids were mainly present in EAPF, such as chlorogenic acid (C₁₆ H₁₈ O₉ ), gallic acid (C₇ H₆ O₅ ), vanillic acid (C₈ H₈ O₄ ), ferulic acid (C₁₀ H₁₀ O₄ ), epicatechin (C₁₅ H₁₄ O₆ ), catechin (C₁₅ H₁₄ O₆ ), hesperetin (C₁₆ H₁₄ O₆ ), naringenin (C₁₅ H₁₂ O₅ ), hyperin (C₂₁ H₂₀ O₁₂ ), luteolin (C1₅ H₁₀ O₆ ), and so on. Therefore, WGH had the potential to be developed as a natural antioxidant and antibacterial material. PRACTICAL APPLICATION: Our work indicates that WGH contains abundant flavonoids and polyphenols compounds. Therefore, the plant byproducts like WGH may have a promising application as a source of antimicrobial and antioxidant additives.

Techno-economic analysis of a new downstream process for the production of astaxanthin from the microalgae Haematococcus pluvialis

The biotechnological production of the carotenoid astaxanthin is done with the microalgae Haematococcus pluvialis (H. pluvialis). Under nutrient deficiency and light stress, H. pluvialis accumulates astaxanthin intracellularly and forms a resistant cyst cell wall that impedes direct astaxanthin extraction. Therefore, a complex downstream process is required, including centrifugation, mechanical cell wall disruption, drying, and supercritical extraction of astaxanthin with CO2. In this work, an alternative downstream process based on the direct extraction of astaxanthin from the algal broth into ethyl acetate using a centrifugal partition extractor (CPE) was developed. A mechanical cell wall disruption or germination of the cysts was carried out to make astaxanthin accessible to the solvent. Zoospores containing astaxanthin are released when growth conditions are applied to cyst cells, from which astaxanthin can directly be extracted into ethyl acetate. Energy-intensive unit operations such as spray-drying and extraction with supercritical CO2 can be replaced by directly extracting astaxanthin into ethyl acetate. Extraction yields of 85% were reached, and 3.5 g of oleoresin could be extracted from 7.85 g homogenised H. pluvialis biomass using a CPE unit with 244 mL column volume. A techno-economic analysis was done for a hypothetical H. pluvialis production facility with an annual biomass output of 8910 kg. Four downstream scenarios were examined, comparing the novel process of astaxanthin extraction from homogenised cyst cells and germinated zoospores via CPE extraction with the conventional industrial process using in-house or supercritical CO2 extraction via an external service provider. After 10 years of operation, the highest net present value (NPV) was determined for the CPE extraction from germinated zoospores.

Integration of the Process for Production of Ethyl Acetate by an Enhanced Extraction Process

The paper presents a study on the performance of a conventional plant-producing ethyl acetate from ethanol and acetic acid. Process models were compiled in the simulator Chemcad 7. The impact of key parameters on the performance of individual installation nodes was examined by sensitivity analysis. Three installation approaches are presented and compared: two classic with different heat duties and an improved one. An improved technological solution, with a closed circulation of the extractant as well as the azeotrope subcooling for better extraction is demonstrated. The energy and mass balance of the installation were developed. The proposed enhancement of a technology with significantly reduced consumption of the fresh extractant also offers a deep recovery of the raw materials, i.e., ethyl acetate and ethanol from wastewater. We assumed that the same energy consumption relative to the classic strategy consumption of ethanol was reduced from 0.531 to 0.524 t/tproduct (−1.2%), fresh process water from 2.18 to 1.42 t/tproduct (−34.9%), and wastewater 2.36 to 1.61 t/tproduct (−31.8%). By this, the wastewater total organic loading (TOL), as well as chemical oxygen demand were nine times reduced. The major advantage is achieved through subcooling of azeotrope, which improves extraction efficiency, making the organic phase enriched with ethyl acetate. Therefore, the performance of the product separation node and the whole system are improved.

Multi-Objective Assessment of Heat Pump-Assisted Ethyl Acetate Production

Multi-objective (energy–economic–safety) assessment of ethyl acetate production involving a heat pump is presented in this paper. The heat pump is designed to intensify ethyl acetate separation and to reduce the total operating cost. Two ethyl acetate production pathways are upgraded using a heat pump, conventional process and reactive distillation column with a separation unit. Detailed process models including the heat pump environment have been compiled and optimized in the Aspen Plus software. Both benefits and drawbacks of including the heat pump in the processes are evaluated using three different points of view: process energy, economics, and safety. As a result, using a heat pump is highly recommended in both conventional process and reactive distillation column with a separation unit. As a higher level of process integration is achieved using a heat pump, economic aspects are improved; however, safety aspects deteriorate. The final decision on the suitability of using a heat pump depends on whether it is proposed for an existing plant, or a completely new plant is designed. In a new plant, the concept of a thermally coupled process (reactive distillation column with a stripper column) has been proven to be the most promising.

Development of Anhydrous Ethanol Purification: Reduction of Acetal Content and Vapor-Liquid Equilibrium Study of the Ethanol-Acetal Binary System

Acetaldehyde diethyl acetal (herein called acetal) is an important pollutant of anhydrous ethanol. Isobaric vapor-liquid equilibrium (VLE) of an ethanol-acetal binary system was measured using a vapor condensate and liquid circulation VLE still. The experimental data were correlated with Wilson, nonrandom two-liquid (NRTL), and universal quasichemical (UNIQUAC) activity coefficient models, which were found suitable for representing the VLE data. Proper agreements between experimental and calculated VLE data were obtained, which were then confirmed with consistency tests. The applicability of the novel VLE data was demonstrated during an investigation of an anhydrous ethanol purification column. Reduction of the concentration of acetal and other pollutants was examined and optimized in a flowsheet environment. The modeling results were verified in a laboratory with an experimental distillation column, confirming a correct agreement between the results. It must be highlighted that the developed method is suitable for the production of pharmacopeial quality anhydrous alcohol, based on reliable, verified VLE data. The results show the importance of accurate VLE data in critical compositions (low pollutant content); moreover, aiming at high product purity, experimental validation has paramount importance. The consistency between the three platforms (VLE and distillation experiments and flowsheet simulation) confirms the accuracy of the developed method.

Multi-Aspect Comparison of Ethyl Acetate Production Pathways: Reactive Distillation Process Integration and Intensification via Mechanical and Chemical Approach

This paper provides a multi-aspect comparison of selected methods of ethyl acetate production and shows the possibility of further reactive distillation process integration and sophisticated intensification including process stream regeneration. The production pathways were selected with respect to their practical applicability and sufficient experimental and feasibility studies already published. A total of four case studies were designed and compared: conventional process set-up (ethyl acetate is produced in a chemical reactor) is designed as a base case study; reactive distillation with a separation unit is derived from the conventional process set-up. The mechanical and chemical approach to reactive distillation process intensification and integration were assumed: reactive distillation column with a stripper and reactive distillation column with an auxiliary chemical reaction (ethylene oxide hydration). Process models were compiled in the Aspen Plus software. Complex process flowsheets of selected case studies including separation and regeneration were designed and optimized. Three different points of view were applied to evaluate the selected process benefits and drawbacks. Process energy, economy, and safety were assessed. As a result, a reactive distillation column with an auxiliary chemical reaction has been proven to be the most suitable pathway for ethyl acetate production assuming all three evaluated aspects.

Separation of Alcohol-Water Mixtures by a Combination of Distillation, Hydrophilic and Organophilic Pervaporation Processes

It can be stated that in the fine chemical industries, especially in the pharmaceutical industry, large amounts of liquid waste and industrial waste solvents are generated during the production technology. Addressing these is a key issue because their disposal often accounts for the largest proportion of the cost of the entire technology. There is need to develop regeneration processes that are financially beneficial to the plant and, if possible, reuse the liquid waste in the spirit of a circular economy, in a particular technology, or possibly elsewhere. The distillation technique proves to be a good solution in many cases, but in the case of mixtures with high water content and few volatile components, this process is often not cost-effective due to its high steam consumption, and in the case of azeotropic mixtures there are separation constraints. In the present work, the membrane process considered as an alternative; pervaporation is demonstrated through the treatment of low alcohol (methanol and ethanol) aqueous mixtures. Alcohol-containing process wastewaters were investigated in professional process simulator environment with user-added pervaporation modules. Eight different methods were built up in ChemCAD flowsheet simulator: organophilic pervaporation (OPV), hydrophilic pervaporation (HPV), hydrophilic pervaporation with recirculation (R-HPV), dynamic organophilic pervaporation (Dyn-OPV), dynamic hydronophilic pervaporation (Dyn-HPV), hybrid distillation-organophilic pervaporation (D + OPV), hybrid distillation-hydrophilic pervaporation (D + HPV), and finally hybrid distillation-hydrophilic pervaporation with recirculation (R-D + HPV). It can be stated the last solution in line was the most suitable in the terms of composition, however distillation of mixture with high water content has significant heat consumption. Furthermore, the pervaporation supplemented with dynamic tanks is not favourable due to the high recirculation rate in the case of tested mixtures and compositions.

Azeotropes as Powerful Tool for Waste Minimization in Industry and Chemical Processes

Aiming for more sustainable chemical production requires an urgent shift towards synthetic approaches designed for waste minimization. In this context the use of azeotropes can be an effective tool for “recycling” and minimizing the large volumes of solvents, especially in aqueous mixtures, used. This review discusses the implementation of different kinds of azeotropic mixtures in relation to the environmental and economic benefits linked to their recovery and re-use. Examples of the use of azeotropes playing a role in the process performance and in the purification steps maximizing yields while minimizing waste. Where possible, the advantages reported have been highlighted by using E-factor calculations. Lastly azeotrope potentiality in waste valorization to afford value-added materials is given.

Modelling and Optimisation of Multi-Stage Flash Distillation and Reverse Osmosis for Desalination of Saline Process Wastewater Sources

Nowadays, there is increasing interest in advanced simulation methods for desalination. The two most common desalination methods are multi-stage flash distillation (MSF) and reverse osmosis (RO). Numerous research works have been published on these separations, however their simulation appears to be difficult due to their complexity, therefore continuous improvement is required. The RO, in particular, is difficult to model, because the liquids to be separated also depend specifically on the membrane material. The aim of this study is to model steady-state desalination opportunities of saline process wastewater in flowsheet environment. Commercial flowsheet simulator programs were investigated: ChemCAD for thermal desalination and WAVE program for membrane separation. The calculation of the developed MSF model was verified based on industrial data. It can be stated that both simulators are capable of reducing saline content from 4.5 V/V% to 0.05 V/V%. The simulation results are in accordance with the expectations: MSF has higher yield, but reverse osmosis is simpler process with lower energy demand. The main additional value of the research lies in the comparison of desalination modelling in widely commercially available computer programs. Furthermore, complex functions are established between the optimized operating parameters of multi-stage flash distillation allowing to review trends in flash steps for complete desalination plants.