KMPS’ engineering team helped the client design a modular distillation system to recover and purify spent solvents, a process that is vital for the plant’s manufacturing operations. The system was fabricated and delivered under an expedited project schedule to meet a customer specified timeline.

1. Telephone: (201) 267-8670
www.modularprocess.com
Case Study:
Modular Distillation System
to Recover Spent Solvents
KMPS Whitepaper Series

2. M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G
Telephone: (201) 267-8670
www.modularprocess.com
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Case Study: Modular Distillation System to Recover
Spent Solvents and Expand Production Capacity
KMPS’ engineering team helped the client
design a modular distillation system to
recover and purify spent solvents, a
process that is vital for the plant’s
manufacturing operations. The system was
fabricated and delivered under an
expedited project schedule to meet a
customer specified timeline.
 CLIENT: A Fortune 500 Company
 INDUSTRY: Specialty Chemical Ingredients

3. M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G
Telephone: (201) 267-8670
www.modularprocess.com
3
Key Engineering Features
 Turnkey scope of a multi-step separation process to recover and purify
solvents including design, equipment, piping, instrumentation,
fabrication, delivery, commissioning, start-up and performance
guarantee.
 Modular fabrication design was used instead of a more costly stick-build
design, which afforded a shorter schedule.
 Multi-effect distillation: the overhead vapors from the first column was
used as the heat source to boil-up the second column for energy savings.
 Extensive additional heat integration to reduce utility cost (OPEX) versus
current operation.
 Robust control scheme to accommodate variation of feed composition
and product specifications.

4. M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G
Telephone: (201) 267-8670
www.modularprocess.com
4
Core Challenges
 Process modeling of a non-ideal, azeotropic
mixture.
 Potential corrosion and fouling due to salts in
feed.
 Hybrid modular design - largest shippable
footprint to contain large equipment and
piping, modules mated up with a large free
standing distillation column.
 Layout - ensuring all equipment and
instruments are accessible and maintainable
within the modules.
 Minimize site interruption and production
downtime during installation and
commissioning of new system.
An azeotrope refers to when a mixture boils at
constant temperature without a change in
composition. In this case, the azeotrope did not
need to be exceeded so conventional
distillation could be used. However, because of
the converging nature of the vapor-liquid
equilibrium curve or “pinch,” activity
coefficients needed to be carefully selected so
that an accurate number of required
theoretical stages was predicted and the
equipment could be designed properly.

5. M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G
Telephone: (201) 267-8670
www.modularprocess.com
5
Simplified Flowsheet
Water & Solids
Stripper
Column
Solvent
Recovery
Feed
Feed
Interchangers
Recovered
Solvent
Blended Solvent

6. M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G
Telephone: (201) 267-8670
www.modularprocess.com
6
The Solution
KMPS was awarded this job from a repeat customer due to a successful previous project. The client had
recently acquired a new plant-site and was in the process of expanding its manufacturing operations
due to increased product demand. The existing equipment was bottlenecking the process and was also
at the end of its operational lifespan. Due to these considerations, the new system had to be delivered,
installed and commissioned on an expedited schedule with minimal site-interruption and production
downtime.
During the front end engineering phase, KMPS took the client provided project specifications and
modeled the process with proprietary simulation software. Because the solvent mixture was non-ideal
and azeotropic, special care was taken in the selection of vapor-liquid equilibrium data. KMPS used a
value engineering approach and developed a multi-step distillation system that resulted in lower
energy consumption than the existing process due to incorporation of a multi-effect distillation
sequence and extensive heat integration. The general concept was discussed and reviewed with the
client in detail, along with the Process Performance Guarantee that KMPS typically provides.
To address corrosion concerns due to salts in the feed, KMPS proposed using duplex stainless steel
equipment and piping specifications for the front end of the process. In order to eliminate the potential
for fouling, proprietary column internals were used in the first distillation column along with special
considerations in the reboiler design.

7. M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G
Telephone: (201) 267-8670
www.modularprocess.com
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The Solution – Cont’d
After the conceptual design and a proposal for the remainder of scope was accepted by the client,
KMPS started detailed engineering and procurement. PFD’s & P&ID’s were developed and module
design and piping layout began using 3D modeling software. Fabricated equipment was designed and
purchased, and instruments were specified. KMPS participated in a client led HAZOP review, and then
invited the client to participate in a 3D piping review that uses special software to simulate a walk-
through of the modules. This process insured that sufficient access was provided and every component
was accounted for.
While the modules were being assembled, KMPS provided the
client with information to prepare the jobsite for delivery. KMPS
supplied foundation loads, anchor bolt patterns, piping tie-in
coordinates, and electrical drawings. Since the customer opted
to utilize their existing control system, KMPS provided guidance
in the form of a Controls Functional Description. In short, the
client received all the information necessary to perform site
preparations while the modules were being assembled, and
KMPS supported this effort as necessary. Performing these site
activities ahead of module delivery greatly streamlined and
shortened the installation process.

8. M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G
Telephone: (201) 267-8670
www.modularprocess.com
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The Solution – Cont’d
The finalized design included the following:
 Three process modules (each approx. 11’ x 14’ x 80’) &
one stair tower
o (1) Distillation column (66” ID x 55’ T/T in-module)
o (13) Shell and tube heat exchangers
o (6) Centrifugal pumps
o (3) Vessels/drums
 Free standing distillation column with operating
platforms (87” ID x 78’ T/T)

9. M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G
Telephone: (201) 267-8670
www.modularprocess.com
9
The Solution – Cont’d
KMPS shipped the entire project by truck to the job site after the modules had
been assembled. Before the units shipped, a complete Factory Acceptance Test
(FAT) was conducted, insuring that the system was ready for operation. After
installation was complete, KMPS provided commissioning and startup services
which included operator training and a Performance Test.

10. M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G
Telephone: (201) 267-8670
www.modularprocess.com
10
Impact
 KMPS designed, built, and delivered a new modular solvent recovery system
under an expedited schedule in order to meet market demand. The new
system was more energy efficient that the current operation and was
designed for 40% more capacity.
 Modular fabrication allowed the new process plant to be fabricated off-site
while the client performed field installation efforts, drastically reducing
project timeline and man-power requirements.
 Modular fabrication also allowed production to continue operations without
interruption while the new distillation system was being fabricated.

11. M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G
Telephone: (201) 267-8670
www.modularprocess.com
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Why Modular from KMPS?
KMPS used a value engineering approach during the front end engineering phase to
save the client time and money, and also provided a Process Performance Guarantee
to eliminate the risk of non-performance. Our modular fabrication approach to
process systems has many advantages, the main points of which are highlighted
below. To learn specifically how modular fabrication achieves these benefits, please
visit our website: www.modularprocess.com
 Shorter schedule / faster time to market
 Lower cost / lump sum bid / single source
 Minimal plant site interruption / improved safety

12. M O D U L A R P R O C E S S S Y S T E M S | D I S T I L L A T I O N | L I Q U I D E X T R A C T I O N | E N G I N E E R I N G | P I L O T T E S T I N G
Telephone: (201) 267-8670
www.modularprocess.com
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KMPS Products & Services
Customer Inquiry Data
Startup Assistance and
Training
Process Development
(In Collaboration with Client’s
Engineers and Scientists)
Material Balance, PFD’s, Unit Operation
Selection, Process Simulation
Process Design
Equipment Design, P&ID’s, Equipment
General Arrangement
Detailed Engineering
Equipment, Piping, Structural,
Electrical, Instrumentation & Controls
Construction
Modular System
Specialists in Process Design and Construction of Modular Mass Transfer Systems for the
Chemical Processing Industry.
Pilot Plant Testing
(If Required)
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Case Study: Modular Distillation
System to Recover Spent Solvents
Bill Morrocco | Process Engineering Manager
www.linkedin.com/in/williammorrocco
Bill Morrocco has over 20 years of experience in design and
start-up of distillation processes and has a BS in Chemical
Engineering from Rensselaer Polytechnic Institute.