KMPS’ engineering team designed a modular acetic acid recovery and purification system as a critical component of a greenfield biomass to renewable chemicals plant.

1. Telephone: (201) 267-8670
www.modularprocess.com
Case Study:
Acetic Acid Recovery from
Aqueous Fermentation Broth
KMPS Whitepaper Series

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Telephone: (201) 267-8670
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Case Study: Modular System to Recover Acetic Acid
from Aqueous Fermentation Broth Stream
KMPS’ engineering team designed a modular
acetic acid recovery and purification system as
a critical component of a greenfield biomass to
renewable chemicals plant. Liquid-liquid
extraction, distillation and stripping were the
three essential mass transfer processes used in
the system. Prior to detailed engineering, the
extraction process was tested at KMPS’ Pilot
Plant to confirm the conceptual design and
allow for an acetic acid recovery and purity
Process Performance Guarantee.
 CLIENT: A Private Biorefining Company
 INDUSTRY: Renewable Energy

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Telephone: (201) 267-8670
www.modularprocess.com
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Key Engineering Features
 Modular design allowed for the customer to concentrate on the
balance of the greenfield project’s engineering, infrastructure
and on-site construction activities, without interruption.
 A Process Performance Guarantee for the system was
established through a liquid-liquid extraction pilot test.
 The selected solvent for the extraction was one produced on
site in a separate process, and the system was designed such
that solvent losses were minimized.
 The system was designed to accommodate a broad range of
acetic acid feed concentrations.
 A complete control system was provided that afforded robust
control of the process and included alarms and interlocks for
safe operation.
KARR® Column

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Telephone: (201) 267-8670
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Core Challenges
 Processing of an Aqueous Fermentation Broth:
bio-derived aqueous streams have a tendency to
emulsify with solvents in liquid-liquid extraction
columns. The customer had observed the aqueous feed
forming an emulsion with solvents during their
laboratory testing, and were extremely concerned that
this could impact the commercialization of the process.
 Multiple feed compositions and turndown
requirements were evaluated during development of
the Process Performance Guarantee.
 Materials of construction - concentrated acids posed
significant corrosion and safety concerns.
 Layout – accessibility of equipment and
instrumentation for maintenance in a compact area.
 Installation – ensure that the installation of the
modules and extraction column internals did not
disrupt the other engineering and operating activities
taking place at the site.
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.Installation of KARR® plate stack at plant site

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Typical Biomass to Renewable Chemicals
Fermentation Process Block Flow Schematic
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Fermentation
Additional Dist.
Product(s) Purification
Distillation (Solvent
Recovery)
Broth Treatment
Filtration
Centrifuge
Cell Disruption
Liquid-Liquid
Extraction
Solvent Stripping
Recycle
Solvent
Spent
Broth Recycle
Solvent
Extract

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Recovery of Acetic Acid from Fermentation
Broth Using a Low Boiling Solvent
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Fermentation Broth
Acetic Acid
Extraction
Raffinate
Stripping
Solvent
Recovery
Raffinate
Recycled
Solvent
Extract
Recovered
Acetic AcidWaste Water

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The Solution
KMPS was awarded this project due to a successful pilot test which proved that KMPS’ extraction
technology could process the feed material and meet the customer’s recovery specifications. The pilot
test was performed using a KARR® Column – a KMPS proprietary liquid-liquid extraction technology -
and enabled KMPS to provide the customer with a Process Performance Guarantee based on provided
production rates. KARR® columns, due to the reciprocating action of the plate stack (internals), are best
suited for systems that have the potential to emulsify. KMPS’ vast experience in solvent recovery mass
transfer processes gave the customer additional confidence in the conceptual design that was
proposed.
Once the pilot test was complete, KMPS developed a
simulation to model the complete process. Vapor-liquid
equilibrium (VLE) data for the solvent recovery area was
based on past project experience and liquid-liquid
equilibrium data (LLE) was selected based on the analysis
of pilot test runs. The simulation served as the basis of
design for all the major process equipment.
R1
R2
R3
R4
E1
E2
E3
E4
M1
M2
M3
M4
B
A C
F
Ternary LLE phase diagram

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The Solution – Cont’d
KMPS supplied a process design package to the customer, and once approved moved onto detailed
engineering and procurement. PFD’s & P&ID’s were developed and the modules were designed using
3D CAD software. Equipment was designed and purchased, and instruments were specified. A control
system complete with a PLC, I/O modules, control panel and HMI was designed and programmed to the
customer’s specifications. PLC was integrated into the overall plant DCS. A customer led HAZOP review
was performed and then necessary alarms and safety interlocks were implemented into the control
system.

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The Solution – Cont’d
A key design feature in the recovery area made use of a vapor side draw to separate the recovered
acetic acid from a less volatile acid in the bottom of the solvent recovery column, enabling the system
to meet the customer’s product purity specification and minimize the required processing equipment.
Also, to address potential corrosion concerns, KMPS suggested using Alloy 2205 stainless steel for
equipment and piping where acetic and sulfuric acid were concentrated.
Prior to modular assembly, the customer participated in a “walk-through” of the module’s equipment
layout and piping using a 3D model generated by CAD software. This allowed the customer to become
more acclimated with the modules prior to installation, and allowed KMPS to ensure that all equipment
and instrumentation were accessible.
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. Performing these site
activities ahead of module delivery greatly streamlined and
shortened the installation process. After the modules were
delivered KMPS supervised the installation of the modules and
the KARR® column plate stack and drive, and provided
commissioning and startup support.

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Telephone: (201) 267-8670
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The Solution – Cont’d
The finalized design included the following:
 (2) Process modules
(Each approx. 11’6” x 14’ x 60’)
o (1) KARR® LLE column
(22” ID x 51’ T/T)
o (1) Solvent recovery column
(34“ ID x 43’ T/T)
o (1) Waste water stripper
(8“ ID x 19‘ T/T)
o (4) Vessels
o (7) Heat exchangers
o (4) Mag drive centrifugal pumps

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Telephone: (201) 267-8670
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Impact
 KMPS designed, constructed and delivered an acetic acid recovery system critical
to the success of the customer’s greenfield plant and overall process. The
modules were delivered to the site 34 weeks after detailed engineering began.
 KMPS’ solvent recovery experience, liquid-liquid extraction technology, and
upfront pilot testing resulted in a modular system that was successfully started
up and met all performance specifications.
 Modular construction allowed KMPS to design and construct the system off site,
allowing the customer to focus on up and downstream process engineering,
infrastructure and other balance of plant activities while also reducing schedule,
cost, and their overall man-power requirements.

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Telephone: (201) 267-8670
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Why Modular from KMPS?
For this project, KMPS leveraged its Pilot Plant capabilities, proprietary extraction
technology, and experience designing solvent recovery systems which resulted in a
complete Modular Acetic Acid Recovery system that was supplied with a Process
Performance Guarantee. 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

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Telephone: (201) 267-8670
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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: Acetic Acid Recovery
from Aqueous Fermentation Broth
Brendan Cross | Process Engineer
www.linkedin.com/in/brendancross
Brendan has over 10 years of experience on chemical separation
processes, including: continuous and batch processes involving
distillation, liquid-liquid extraction, stripping and absorption. Brendan
has a BS in Chemical Engineering from Columbia University.