Distillation and separation modules
Functional process modules for heating, evaporation, separation, cooling, condensation and preparation of liquid, vapor and gas–liquid streams
Modular construction of process lines
Distillation and separation processes can be formed from separate functional modules, each of which performs a specific process step: feed preparation, heating, evaporation, phase separation, cooling, condensation or collection of the output streams.
The modular approach can provide a new plant, extend an existing process line or replace individual equipment sections. The composition, sequence and design of the modules are determined by feed stream properties and the required output specifications.
Applications
Main tasks of modules
Feed preparation
Feed receipt, storage, filtration, mixing and transfer to downstream stages
Controlled heating
Controlled heat input to a liquid or solid feed under the selected operating conditions
Evaporation of volatile components
Transfer of water, solvents or light fractions into the vapor phase
Phase separation
Separation of liquid, gas and solid phases in the sequence provided by the process flowsheet
Vapor cooling
Reducing the temperature of a vapor or vapor–gas stream before condensation
Condensation
Condensation of the target vapor components
Collection of output streams
Separate accumulation of the main product, water, organic condensate and solid impurities
Automated control
Monitoring process parameters, equipment status and safety interlocks
Advantages of modular design
Configured for the application
The equipment package is selected for feedstock properties and the required separation
Phased system development
Individual modules can be commissioned sequentially
Modernization of existing equipment
New functional modules can be integrated into an existing process line
Scalability
Capacity can be increased by selecting larger equipment or installing modules in parallel
Factory-built modules
Individual units can be supplied with piping, instrumentation and control system
Reduced on-site work
Pre-assembly of equipment reduces the amount of installation work on site
Ease of maintenance
Dividing the installation into functional sections simplifies access to individual components
Integrated automation
Control of individual modules can be combined into a common system
Process module options
The equipment package is selected taking into account the physical state of the product, temperature, pressure, water content, volatile components, mechanical impurities and requirements for the resulting process streams.
Main stages of the process flowsheet
- Reception of the feedstock
- Sampling and characterization
- Pre-filtration if necessary
- Storage and equalization
- Feeding the product into the process unit
- Controlled heating
- Evaporation of target components
- Removal of vapor or vapor–gas stream
- Gas-liquid separation if necessary
- Flow cooling
- Vapor condensation
- Separation of liquid phases if necessary
- Collection of main product and condensate
- Return of working gas where a recirculation loop is included
- Testing the output streams
Not all of the steps listed apply simultaneously. The composition and sequence of modules are determined by a specific process requirement.
Feed preparation module
Before entering the main process units, the feed may need storage, equalization, removal of coarse solids and pre-filtration. The pretreatment section depends on the feed's physical properties and contamination level.
Heating and evaporation module
The module provides a controlled supply of heat to the product and creates conditions for the evaporation of water, solvents or other volatile components. The operating mode is determined by the composition of the feed stream and the permissible processing temperature.
The design of the heating section and the method of heat transfer are selected individually. The equipment type is selected once the process flowsheet has been confirmed.
Distillation module
The distillation module separates components by volatility. Lighter components vaporize and flow to the cooling and condensation section.
Feedstock testing determines the number of stages, operating temperatures and process arrangement. The module is configured for the application.
Separation modules
Separation modules are designed to separate gas, liquid and gas-liquid flows. The design and internal devices are selected taking into account the composition, flow rate, density and physical state of the separated phases.
Cooling and condensation
The vapor or vapor–gas stream leaving the process unit enters the cooling system. Target components condense and are collected in receiving vessels.
The condensation module can work in conjunction with a gas-liquid separator and a liquid phase separation system. The equipment package is determined by the properties of the vapors and the requirements for the condensate.
Working gas circulation
In certain process flows, a working or inert gas may be used to transfer water vapor, solvents and other volatile components from the heated product to the cooling and condensation system.
Once the condensable components have been separated, the gas can be returned to the process. The type of gas, flow rate, pressure and circulation mode are determined by the project.
Modular line equipment
The final equipment package follows the approved process flow diagram. Individual items are used only when necessary.
Equipment configurations
Functional modules may be supplied as individual units, frame-mounted assemblies or parts of a complete plant. Their design depends on required throughput, site conditions and transport and installation constraints.
Lower-throughput laboratory and pilot units can be used to establish operating conditions and verify the process flowsheet.
Resulting process streams
Primary liquid product
Liquid fraction after the processing provided by the process flowsheet and removal of some volatile components
Water condensate
Water separated from the feedstock and collected after cooling the vapor stream
Organic condensate
Solvents or light hydrocarbon components that become liquid after cooling
Gas stream
Gas after removal of entrained liquid droplets and condensable components
Solid impurities
Mechanical impurities and sediments separated at the preparatory or separation stages
Options and configurations
Feed preparation module
Reception, accumulation, filtration, mixing and supply of the feedstock
Heating and evaporation module
Equipment for controlled heat input and devolatilization
Distillation module
Process equipment and auxiliary equipment for separating components by volatility
Separation module
Equipment for separation of gas, liquid and solid phases
Condensing module
Coolers, condensers, separators and liquid collection tanks
Complete modular installation
Sequential integration of preparation, heating, separation, cooling, condensation and automated control
How modules are selected
- Review of project data
- Determination of the composition and physical state of the product
- Determination of water and volatile components
- Determination of mechanical impurities
- Temperature evaluation
- Determining the required separation
- Clarification of requirements for output streams
- Laboratory tests
- Pilot tests if necessary
- Selection of process stages
- Selection of individual modules
- Development of equipment connection diagram
- Control system selection
- Preparation of technical proposal
The final equipment package is selected after feedstock analysis. No single module is suitable for every process application.
Delivery and implementation
Available equipment configurations
Related Solutions
Distillation, regeneration and clarification of petroleum products
Complex processes for the separation, recovery and stabilization of liquid petroleum products
Solvent and moisture removal
Removal of water and volatile components from liquid industrial products
Regeneration of used oils
Filtration, dehydration and removal of volatile components from used oils, with suitability for reuse assessed by testing
R&D and laboratory research
Experimental verification of separation conditions and preparation of design input data
We will configure the process modules for your application
To prepare a technical solution, information is required on the feed composition and flow rate, physical state, water and volatile-component content, operating parameters, existing equipment and requirements for the output streams.