Butyraldehyde Tower Capacity Limitations

The Main Distillation tower in the only Oxo Alcohol Plant in South America was revamped in 2004.  The tower experienced capacity limitations from the start.  A study of the column capacity was enacted in 2005.  New trays were provided in 2007.  The capacity only increased marginally with the new trays.  In 2008 another detailed capacity study was enacted including gamma scans of the tower.  During this study, the top few trays showed unusual absorption on the Gamma Scans.  The buildup of water in the tower was suspected.  The spare pump line was drained and found to be totally full of water.  However, upon further draining, an abundance of foam came out of the spare pump line.  This paper will detail the lessons learned from this experience and the ultimate solution to this very interesting tower.