Resolving Fouling and Performance Issues Through Process Simulation
The Challenge

In 2017, GlaxoSmithKline (GSK) and its partners approached Rosenberg to investigate operational issues with an MIBK (Methyl Isobutyl Ketone) Steam Stripper at the Irvine, Scotland facility.

Originally installed in 1985, the column was experiencing tray fouling, high pressure drop and reduced product purity.

Our Solution

Rosenberg carried out a detailed process and hydraulic simulation of the column, analysing temperature and vapour-liquid profiles across both minimum and maximum operating cases.

The MIBK-water system was modelled using the DECHEMA K-value method, incorporating UNIQUAC thermodynamics and Antoine vapour pressure correlations.

The study identified opportunities to improve stripping efficiency through the use of dry, superheated steam and preheating of the contaminated MIBK feed.

Importantly, the analysis also identified the underlying cause of the recurring fouling. The existing sieve trays were operating across an excessively wide range during batch operation, alternating between dry operation, weeping and jet flooding. This unstable hydraulic behaviour was a major contributor to the fouling and associated performance issues.

The Result

Rosenberg’s simulation provided a clear understanding of the column’s operating limitations and identified the process and hydraulic conditions responsible for its poor performance.

The study established a basis for improving stripping efficiency, reducing fouling and achieving more stable operation, demonstrating the value of detailed process simulation when troubleshooting existing mass transfer equipment.

Process Simulation | Fouling Analysis | Hydraulic Optimisation | Improved Stripping Performance