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SEPARATIONPROCESSESfrom first concept to

guaranteed plant performance

bdv_Prozesstechnik 15.06.2004 8:10 Uhr Seite 13

KÜHNI process technology is appliedthroughout the entire process indus-tries. However, due to our specificknow-how, the emphasis is placedon the following areas of specialitychemicals and life sciences:

� pharmaceutical � fine chemical, agrochemical,

dyestuff, pigments� biotechnology� foodstuffs

Many of the world’s leading compa-nies in each of the above markets,regularly call upon KÜHNI‘s expertiseto provide them with innovative solu-tions to their separation problems.KÜHNI is globally active, workingthrough a network of agents, in all ofthe important markets.

C u s t o m e r sS c o p e o f W o r k

KÜHNI has long since been renown-ed as a world-wide, specialist sup-plier of state of the art technology, in the field of thermal and diffusionalseparations, as well as membraneprocesses. Its process technology isbased upon innovation, outstandingcompetence, and many years, exten-sive experience.

The vast majority of processes devel-oped are tailor-made solutions to cus-tomer-specific problems. The mainfield of activity is the separation oforganic, and organic/aqueous mix-tures in the following three areas:

� solvent recovery � product purification � recovery of valuable products

from waste water or vent streams

KÜHNI Separation

Processes

In addition to its range of high per-formance process equipment, KÜHNIoffers its customers the advantage of complete process solutions, withtotal responsibility in one hand.KÜHNI is able to provide turn-keyprocess plants, through the use of itsown in-house staff.

In the area of separation processes,our scope of supply includes:

� process synthesis and develop-ment

� laboratory and pilot scale testing, and toll manufacture

� basic and detailed engineering� supply of key equipment� plant supply – either skid mount-

ed or site-built


U n i t O p e r a t i o n s

KÜHNI has developed from an equip-ment fabricator, to a modern technol-ogy oriented company. An importantstep was the development of its ownhigh quality process components,starting with the legendary KÜHNIRing-tunnel tray, used in liquid airseparation. Today, KÜHNI’s technolo-gy portfolio covers the following unitoperations:

� distillation / rectification� film evaporation� liquid-liquid extraction� absorption / stripping� continuous reaction

M e m b r a n e P r o c e s s e s

K Ü H N I H i g h - p e r f o r -m a n c e C o m p o n e n t s

For some considerable time, KÜHNIhas also been involved in membraneseparation processes. KÜHNI’s suc-cessful introduction of this technolo-gy started with the use of pervapo-ration, a technology complementaryto distillation, for the separation ofazeotropic mixtures. However, todayKÜHNI is active in a much widerrange of membrane processes,including:

� pervaporation, vapour permeation� nano-filtration, reverse osmosis� membrane based liquid-liquid

extraction

Distillation / absorption

� ROMBOPAK®‚� slit trays

Liquid-liquid extraction

� agitated columns� packed columns� mixer-settlers

Film evaporation

� falling film evaporators� wiped film evaporators� short path evaporators

Continuous reaction

� multi-compartment column reactors


Process Synthesis

and Development

P r o c e s s G u a r a n t e eT e s t i n gI n i t i a l c o n c e p t

A structured, analytical approach iskey to developing the optimum pro-cess, for a particular separation prob-lem. A full understanding of theinherent system limitations as wellas relevant properties of componentsand mixtures is required.

KÜHNI engineers use the followingtools and methods to analyse thesystem and to develop separationsequences leading ultimately to theoptimal, overall process:

� know-how/experience � on-line literature search� process synthesis

(Hysis Distil) � computer simulation

(ChemCad and Hysis Process)� laboratory/bench scale testing.

Following the initial screening of pos-sible processes, laboratory scale ormini-plant tests are undertaken onthe most interesting solution(s), withthe following objectives:

� confirmation of the results ofcomputer simulations

� optimisation of the operatingparameters

� consideration of the effects ofunknown or trace components

� process stability� membrane screening.

For scale-up purposes, pilot planttests are undertaken in our moderncomputer controlled test centre.Samples of large quantities can beproduced for further customer tests (re-use tests, market introduction).The following plants are available:

� distillation columns with packingor trays

� falling film, wiped film and shortpath evaporators

� packed and agitated liquid-liquidextraction columns, and mixer-settlers

� membrane test units.

The successful completion of pilotplant tests enables KÜHNI to providefull process guarantees.


P r o j e c t , Q u a l i t y M a n a g e m e n tB a s i c E n g i n e e r i n g

Following sanction, the project thenmoves into the detailed engineeringphase, resulting in:

� final P&IDs, equipment andinstrument specifications

� manufacturing drawings for keyequipment

� 3-D plant model� piping isometrics� automation� DQ documentation.

KÜHNI has over 40 years experiencein the design of separation plants.This experience is complemented bymodern software/tools, which help tostreamline the amount of engineer-ing work required.

Throughout the complete project, theProject Manager is in close contactwith the customer, and co-ordinatesthe respective members of the in-house project team. The ProjectManager has overall responsibility forthe project budget, schedule andquality.All stages of every KÜHNI project aregoverned by a Quality AssuranceSystem which is accredited in accor-dance with ISO9001:2000. Procure-ment is undertaken in accordancewith well defined procedures, fromapproved suppliers.Standard procedures, protocols andtest documentation are used fromdesign through to performance quali-fication.

D e t a i l e d E n g i n e e r i n g

The information gained from processsynthesis and, or, pilot plant testingis fed back into the design of theplant, and the initial concept is thenfurther developed, through the basicengineering phase, resulting in:

� PFD and heat and mass balances � P&I diagrams � equipment specifications� instrument specifications� functional design specification � preliminary equipment layout� capital cost estimate.

Each of the above activities areundertaken by highly qualified andexperienced in-house staff, workingunder the guidance of the ProjectManager.

Engineering and

Project Management


Equipment Manufacture

and Skid Assembly

K e y E q u i p m e n tS k i d M o u n t e dP l a n t s

Key equipment, including, but notlimited to, columns, column internals,extractors and film evaporators areproduced in a modern workshop,with efficient manufacturing process-es. The range of possible materials ofconstruction includes stainless steels,special alloys as well as titanium, zirconium, and tantalum.All equipment for European custom-ers fulfils the requirements of thePED regulations. KÜHNI is also certi-fied to manufacture equipment ac-cording to US standards with the U-Stamp. Design codes include ADMerkblätter, Codap, SVTI as well asASME VIII. All welding proceduresare certified in accordance with EN729-2.

The supply of KÜHNI process plantsin modular, skid mounted form, is ofever increasing interest to our cus-tomers.Skid mounted plants offer manyadvantages including:

� short delivery time� low overall investment costs� reduced amount of on-site

erection� manufacture of the complete

plant under workshop conditions,ensuring highest quality

� completion of factory acceptancetests prior to delivery

� partial completion of IQ/OQ priorto plant delivery.

KÜHNI has supplied more than 100skid mounted modules over the past15 years. Specific know-how hasbeen developed, particularly with thedesign of large modules, to take intoaccount horizontal assembly andtransport followed by off-loading anderection into the vertical position.

Skids are assembled in a modern,purpose built workshop which is fit-ted with the latest equipment, includ-ing orbital welding stations, and CNCpipe bending equipment.

Considerable experience has beengained in the transportation of largeskids throughout Europe, and to Asiaand the USA. Skids of up to 4m x 5mx 20m, have been shipped in one-piece. Larger plants are broken downinto individual modules for shipment.


Site Services and

Hand-over

KÜHNI has a team of highly expe-rienced installation supervisors, whoare responsible for site managementduring the construction phase of site-built plants, and the off-loading,installation and mechanical testing ofskid mounted plants. KÜHNI’s site supervisor liaises close-ly with the customer’s Safety Officerand mechanical services contractor,to ensure a safe and trouble freeinstallation.

Following completion of the cus-tomer’s mechanical and electrical tie-ins to the plant, KÜHNI engineers aredespatched to site to undertake plantcommissioning. The KÜHNI commis-sioning team consists of the processengineer responsible for the designof the plant, and the automation engi-neer.Plant commissioning is undertaken ina structured manner, through watertests and running with product, to afinal guarantee run and plant hand-over. Training of the customer’s oper-ators is often undertaken in parallel.

The plant is supplied with all the necessary documentation, includingfinal versions of the following:

� P&ID� equipment specifications� pump manuals� instrument specifications� instrument manuals� equipment drawings� plant layout� test certificates � material certificates � certificates of conformity� DQ/IQ/OQ/PQ documentation.

C o m m i s s i o n i n g F i n a l D o c u m e n t a t i o nI n s t a l l a t i o n


KÜHNI has extensive experience inregeneration and recovery of sol-vents. Some typical examples are:

� Non-Azeotropic SystemsMethanol/water, acetone/water,DMF/water, dimethyl acetami-de/water, NMP/water, aceticacid/water, methanol/ethanol,ethyl acetate/toluene, DCM/ ethylacetate, DCM/pyridine, IPA/methoxyethanol.

� Heterogeneous Azeotropic SystemsButanol/water, ethyl acetate/water, n-butyl acetate/water,MIBK/water, triethyl amine/water, MEK/water, dichloro-methane/water, toluene/water,dichloroethane/water, xylene/water/methanol, hexane/water/methanol.

� Homogeneous Azeotropic SystemsEthanol/water, IPA/water, THF/water, acetonitrile/water, phe-nol/water, pyridine/water, ethylacetate/cyclohexane, ethyl ace-tate/ethanol, DCM/methanol,methanol/dioxane, methanol/ortho-dichlorobenzene, hexane/methanol/butane, methanol/IPA/tertiary amyl alcohol, cyclohex-ane/ethyl acetate, acetic acid/ethyl acetate, THF/ethyl acetate,decane/THF/ethyl acetate, meth-anol/xylene, acetone/methanol.

Recovery techniques involve simplerectification, azeotropic distillation,extractive distillation, pressure-swingdistillation, liquid-liquid extraction,pervaporation and vapour perme-ation, or hybrid processes using acombination of these.

In the area of product purification,KÜHNI’s experience can be dividedinto rectification/stripping, film evapo-ration and liquid-liquid extraction pro-cesses. Some typical examples are:

� Vacuum Rectification, StrippingRectification of heat sensitiveproducts at low pressures as wellas stripping of low boiling compo-nents requiring a number of sep-aration stages, as e.g.

Toluene/NMP/herbizide, octade-canol/additive, methanol/water/toluene/fruit aroma.

S o l v e n t R e c o v e r yP r o d u c t P u r i f i c a t i o n

Kühni Process Experience


� Film EvaporationSimilarly to rectification, productpurification by film evaporation isundertaken at very low pressure.It can be used to concentrate theproduct, remove traces of lowboiling contaminants, as well ashighly viscous or high boiling by-products. Typical applications are:

Amino acids, sugars, polymers,thio-glycols, acrylic products,esters, fatty acids and deriva-tives, fatty alcohols, pharmaceu-ticals, resins.

� Liquid-Liquid ExtractionLiquid-liquid extraction is also akey technology for product purifi-cation. Typical examples are:

Pharmaceuticals, vitamins, agro-chemicals, flavours, wet purifi-cation of precious metals, wool-wax alcohol.

KÜHNI’s activities in waste waterand vent gas treatment are focusedupon regenerative techniques, forthe recovery of valuable compo-nents.

Examples for waste water:

� Steam Stripping Methanol, MTBE, dioxane,ethanol, ethyl acetate, butylacetate, iso-propanol, butanol,MEK, MIBK, DCM, toluene, iso-propyl ether, ammonia/water.

� Liquid-Liquid Extraction Acetic acid, phenol, DMF,DMAC, NMP, agrochemicals,pesticides.

Examples for vent gases:

� Absorption with waterMethanol, ethanol, IPA, acetone,ammonia.

� Absorption with high boiling oilfollowed by steam strippingComplex mixtures of hydro-carbons, alcohols, chlorinated hydrocarbons, ketones, ethers,esters etc.

W a s t e W a t e r /V e n t G a s Tr e a t m e n t


Hybrid Plants

The optimum solution to a sepa-ration problem often involves theimplementation of hybrid processes.

Hybrid processes can be defined asthe combination of two or more sep-aration steps, which are based upondifferent physical separation pheno-mena.

They are often applied to difficult sep-arations, or where very high puritiesare required. Additionally, they caneliminate the need to use entrainersor extractants, and quite often lead tothe minimum energy requirementsand thereby operating costs.

The development of hybrid proces-ses is a complex procedure. By theirvery nature, they often involve anumber of unit operations, and inter-nal recycle streams. This leads to alarge number of degrees of freedom,and the engineer has to determineboth the optimum working conditi-ons for each of the unit operationsand the conditions at each respectiveinterface .

Liquid-liquid extraction very oftenleads to a hybrid process, due to theneed for solvent removal from bothraffinate and extract streams. This isusually done by distillation.For the majority of cases, membraneseparations also benefit from beingcombined into a hybrid process, par-ticularly in the field of the fine chemi-cal and pharmaceutical industries.

� Distillation/ExtractionTHF/water, pyridine/water, aceticacid/water, phenol/water, THF/hexane, DCM/ethanol, ethylacetate/methanol

� Distillation/Membrane StepEthanol/water, IPA/water, methylacetate/water, pyridine/water,IPA/butyl acetate/water, acetone/water/API

� Absorption/DistillationNH3 recovery from vent streams,VOC abatement with high boilingliquids

T y p i c a l E x a m p l e s


KÜHNI has come a long way from itsbeginnings as an equipment fabrica-tor, to an innovative supplier of pro-cess systems. The major mile-stoneshave been:

� 1960ssupply of the first turn-key plant,first test centre

� 1980sthin film evaporation technologyadded to the KÜHNI portfolio,Rombopak structured packingdeveloped and patented,relocation to purpose built mod-ern facilities,supply of the first skid mountedplant

� 1990ssupply of the first hybrid plantincorporating a membrane step,ISO9001 accreditation

� 2000supply of the largest, modularsolvent recovery plant including 6skids, supply of the first skidmounted plant to Asia

� 2001accreditation for the ASME U andS stamp,supply of the first skid mountedplant to the USA,awarded with Basel’s Prize forInnovation for “Large ModularProcess Plants – an InnovativeConcept”

� 2002100th skid module completed,remote trouble-shooting and com-missioning via dial-up/VP net-works

� The future process synthesis using state ofthe art tools,additional innovative hybrid pro-cesses using membranes, expansion of the KÜHNI test cen-tre for extreme operating condi-tions and toxic products, elimination of skid transportrestrictions through cargo-lift,OQ of modular plants prior toshipment

M i l e - s t o n e s

The Future


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O u re x p e r t i s e :

O u r s c o p eo f s u p p l y :

� Distillation

� Evaporation

� Extraction

� Absorption

� Membrane technology

� Chemical reaction

Environmental technology

� Process development

� Laboratory and pilot testing

Engineering

� Process equipment

� Turn-key process plants

� Toll separation

KÜHNI LTDSeparation Processesand Technologies

Gewerbestrasse 28P.O. Box 51CH-4123 Allschwil 2Telephone (+41) 61/486 37 37Fax (+41) 61/486 37 77E-Mail [email protected] www.kuhni.ch

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bdv · 2.07 · 2000 SP e


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