Use of Distillation Simulation and Process Analysis Techniques in Toll Manufacturing: A Case Study

Because of scheduling issues or lack of appropriate equipment, chemical companies often use the services of small toll manufacturers to produce products for customer trials or to meet unexpected product demand. In 2012, Cytec Industries required the distillation services of a toller to upgrade the quality of one of its raw materials containing two closely boiling isomers. Since the process is carried out in a batch reactor, the mass of the batch could then be increased and the batch reaction cycle time reduced to meet an unexpected demand for the final product.

This paper is a case study in the use of distillation simulation and process analysis techniques to guide the selection process for an appropriate toller, develop the operating parameters for the distillation campaign, and provide day-to-day direction for the campaign to overcome unexpected timeline challenges caused by lower than anticipated column efficiency, a power outage, a pump seal failure, and underperfomance of a rented cooling water chiller.