Chemical Engineering and Processing 49 (2010) 139146

Contents lists available at ScienceDirect

Chemical Engineering and Processing:

Process Intensication
journal homepage: www.elsevier.com/locate/cep

Dividing wall columns: Fundamentals and recent advances

Norbert Asprion , Gerd Kaibel
BASF SE, Carl-Bosch-Str.38, 67056 Ludwigshafen, Germany

a r t i c l e

i n f o

Article history:
Received 5 January 2010
Accepted 19 January 2010
Available online 25 January 2010
Keywords:
Dividing wall column
Thermally coupled distillation sequences
Energy-efcient distillation

a b s t r a c t
Different distillation sequences for the separation of near-ideal multicomponent mixtures have been
proposed in the past. These sequences included both conventional and thermally coupled distillations.
Investigations of these sequences based on thermodynamics and steady-state simulations aimed for
identifying the economic and energetic favourable conguration. Dividing wall columns have shown to
be superior to conventional distillation sequences in certain cases. For this reason dividing wall columns
gained increasing application in the last years. More than 90 applications in production scale are known.
The advantages are obvious. Depending on the case considered the energy and investment costs are
reduced up to 30% compared to conventional technologies. The footprint is signicantly smaller. Also
advantageous is the higher exibility of these systems in comparison to conventional column sequences.
For temperature-sensitive products the thermal stress is reduced since the product is reboiled only once.
Especially for high price products the product quality can be raised by simultaneously increasing the
separation yield.
An overview about fundamentals, applications, limitations and recent advances will be given in the
paper.
2010 Elsevier B.V. All rights reserved.

1. Introduction
Industrial distillation processes are highly energy-consuming
operations. Therefore extensive research about different congurations for the separation of near-ideal multicomponent mixtures has
been triggered. Especially thermally coupled distillation columns
have been investigated (see e.g. Petlyuk et al. [1], Stupin and Lockhart [2] and Fidkowski and Krolikowski [3]). These concepts are the
basis of the dividing wall column.
Considering a near-ideal three component mixture consisting of components A, B and C with A the lowest boiling and C
the highest boiling component a lot of different congurations
of distillation columns are possible. A simple way to analyse
different column congurations for the separation of this mixture is the use of the network presentation shown on the left
side in Fig. 1 (cf. e.g. Agrawal [4] or Sargent and Gaminibandara
[5]). Here the feed is a node and a line represents a separation
sectioneither a rectifying or stripping section. As can be seen the
maximum number of separation sections is six for a three component mixture (n(n 1) sections for a n component mixture). Any
conguration with less than six sections cannot produce reversible
splits (cf. Petlyuk et al. [1]). To avoid mixing entropy (i.e. to perform a reversible split) in each section only the highest and the

Corresponding author. Tel.: +49 621 60 498 49; fax: +49 621 60 790 20.
E-mail address: norbert.asprion@basf.com (N. Asprion).
0255-2701/$ see front matter 2010 Elsevier B.V. All rights reserved.
doi:10.1016/j.cep.2010.01.013

lowest boiling components should be separated (cf. e.g. Kaibel

[6]).
In the super-structure of Sargent and Gaminibandara [5]1 shown
on the right side of Fig. 1 each rectifying section has one condenser
and each stripping section has one reboiler. So in total there are six
heat exchangers (reboilers and condensers). This number can be
reduced by the use of thermally coupled columns as will be shown
in Fig. 2.
For the separation of the three component mixture into pure
products at least a sequence of two simple distillation columns
is needed. Each of these columns has a rectifying and a stripping
section. So the minimum number of column sections is four to
receive pure products2 . If one reboiler for each stripping section
and one condenser for each rectifying section is used, than this
leads to the conventional distillation sequences: direct and indirect split, which are shown in Fig. 2a and b with in total four

1
This super-structure does not cover all possible congurations as has been
discussed by Agrawal [4] and Christiansen et al. [7], since Sargent and Gaminibandara considered only sequences of n 1 column, but also satellite conguration of
columns around a central column are possible (cf. Agrawal [4]) and also less columns
(e.g. two columns for a four component mixture are possible (cf. Kaibel [6] and
Christiansen et al. [8]).
2
A typical side-stream column with 3 separation sections for the separation for a
three component mixture is not considered here, since it is not possible to get a pure
component B. The side product is contaminated either by the low boiling product A
when the side-draw is located in the rectifying section or respectively by the high
boiling product C, when the side-draw is placed in the stripping section.

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N. Asprion, G. Kaibel / Chemical Engineering and Processing 49 (2010) 139146

Fig. 1. Network presentation and super-structure (see footnote 1) for a separation of a three component mixture into pure products.

reboilers and condensers. But as stated above these congurations

are not possible to perform reversible splits and will therefore
in general need more energy for the separation than reversible
splits.
Another conguration with only two columns but six separation sections is shown in Fig. 2c. This is a thermally linked column
where the intermediate reboiler and condenser of Fig. 1 have
been removed and the two columns on the right were combined
to one. The next three congurations show also three thermally
coupled distillation columns: the side-rectier (Fig. 2d), the side-

stripper (Fig. 2e) and the fully thermally coupled column (or
Petlyuk column, Fig. 2f). Compared to the conventional distillation
schemes these congurations need less heat exchangers. Additionally the fully thermally coupled column needs less energy than
the conguration of Fig. 2c since no parts of the separation will
be performed twice (cf. Poth et al. [9]). For example the siderectier conguration as can be seen in the network presentation
is similar to the direct sequence. Here the stripping sections are
combined and use the same reboiler. From an energetically point
of view in general no lower consumption can be expected, but

Fig. 2. Possible congurations for a separation of a three component mixture into pure products: (a) direct split, (b) indirect split, (c) thermally linked column, (d) side-rectier,
(e) side-stripper and (f) fully thermally coupled.

N. Asprion, G. Kaibel / Chemical Engineering and Processing 49 (2010) 139146

141

Fig. 3. Basic types of dividing wall columns for the separation of a three component mixture: integration of (a) side-rectier (cf. Fig. 2d), (b) side-stripper (cf. Fig. 2e) and (c)
fully thermally coupled column (cf. Fig. 2f) in one column shell.

one reboiler less is needed (but on the other hand the second
reboiler and the rst column at least in the lower part have to be
bigger).
Especially if both columns are integrated within one shell investment is reduced. These are the so-called dividing wall columns. The
dividing wall columns for the side-rectier and the side-stripper
conguration are shown in Fig. 3a and b. For the fully thermally
coupled column conguration it is presented in Fig. 3c. This last
conguration offers the potential of signicant lower investment
and energy consumption (up to 30%, cf. Kaibel [6], Christiansen et
al. [8], Agrawal and Fidkowski [10]) compared to the conventional
distillation schemes. The standard dividing wall column (Fig. 3c)
has found broader application than the congurations in Fig. 3a
and b.
Wright [11] proposed the rst dividing wall column and it took
nearly 40 years for industrial application in production scale. In the
following some general remarks about dividing wall columns will
be made and a brief summary of applications and recent advances
will be given.
2. Dividing wall columns in technical application
In 1985 dividing wall columns found rst industrial application
in BASF. In the mean time more than 60 dividing wall columns

have been implemented in industry within BASF and under BASF

licenses.
2.1. Construction details of dividing wall columns
The dividing wall prevents the lateral mixing of liquid and
vapour streams. The dividing walls are vertical partitions formed by
at metal sheets, which are either welded to the column shell (cf.
Fig. 4) or consist of exible thin metal sheets which are stacked
together (cf. Fig. 5). When structured packings are applied, the
positioning of the dividing wall and the welding procedure must
be done carefully. Wall ow should be avoided since it would
deteriorate the purity of the products. Especially in cases of poor tolerances of the column shell this can lead to difculties. The thin wall
elements which are stacked together without welding (cf. Fig. 5,
development of Montz) are more convenient as they provide more
space to the crew and allow a thorough and precise assembling.
This construction is supported by self-centering packing elements.
These elements in combination with the exible dividing wall can
compensate poor tolerances of the column shell. At present this system has become the standard solution. The stacked wall elements
can also be applied in tray columns.
The additional stress due to welded dividing walls can be
checked by nite element calculations taking into account sev-

Fig. 4. Welded dividing wall (photos provided by Montz).

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N. Asprion, G. Kaibel / Chemical Engineering and Processing 49 (2010) 139146

Fig. 5. Stacked metal sheets as dividing wall (development of Montz, Patent EP1088577).

Fig. 6. Bend of a column (a) without and (b) with dividing wall under wind load. Colours are indicating the displacement in mm. (For interpretation of the references to color
in this gure legend, the reader is referred to the web version of the article.)

eral effects like temperature prole, system pressure, dead load

of the column and additional wind load from different directions.
Fig. 6 shows an example of such a calculation. Here the differences
between a column with and without a dividing wall were negligible,
but this has to be checked as the case arises.
Heat transfer across the dividing wall can be avoided by thermal
insulation of the dividing wall. Especially if very high purities are
needed in packed columns, insulation might be useful to suppress
undesired wall ow of liquid. In cases with high temperature differences of more than 40 C on both sides of the dividing wall it
may be advisable to check the mechanical stress of the construction by nite element calculations (cf. Fig. 7). Large temperature
differences may lead to an undesired bend of the column due
to different thermal expansion as a consequence of the temperature differences. The use of a column with symmetric, concentric
arrangement of the dividing wall instead of the conventional design
as shown in Fig. 8 can avoid this bend. Usually the feed plate and
the side-draw are arranged at different heights and their relative
position is determined by the ratios of the relative volatilities of
the components. Mostly the dividing wall is placed in the middle,
but off-center positions of the dividing wall are also possible (see
Fig. 9). This might be useful in situations, when the concentration of
the medium boiling component is small compared to the overhead
and bottom products. Alternatively a small thermally coupled side
column can be used.

Fig. 7. Calculation of mechanical stress in the dividing wall column (according to

Fig. 3b) due to large temperature differences with the nite element method. The red
colour is indicating locations with peak stress. (For interpretation of the references
to color in this gure legend, the reader is referred to the web version of the article.)

N. Asprion, G. Kaibel / Chemical Engineering and Processing 49 (2010) 139146

Fig. 8. Replacement of the conventional design by a symmetric, concentric arrangement of the dividing wall to avoid bends due to large temperature differences.

143

Fig. 11. Parameters in the design of a dividing wall column.

ponent B around the diving wall should be avoided since than the
energy demand is not optimal. This can be adjusted by the liquid
distribution at the upper end of the dividing wall. The gas distribution depends on the cross section and the column internals of the
sections left and right of the dividing wall since pressure drop on
both sides is the same.
Simulation of dividing wall column is a challenging issue. We
recommend to use a simultaneous equation based solver which is
better suited than the use of a sequential solver strategy (see also
Becker et al. [12]). The optimization of the dividing wall column is a
mixed integer non-linear programming (MINLP) problem. For this
task no dedicated commercial software is available at the moment.
2.3. Separation in a dividing wall column

Fig. 9. Off-center position of dividing wall for small amounts of medium boiling
components.

For vapour feeds and/or vapour side-draws a diagonal off-center

position of the dividing wall can be useful (cf. Fig. 10). In this case
almost equal F-factors will be reached in the partitioned sections
of the column.
2.2. Design of dividing wall columns
The design of a dividing column is more complex compared to a
conventional distillation column. While for a conventional column
four parameters have to be xed, for a dividing wall column for a
separation of three components the number of parameter is 11 (cf.
Fig. 11). For a xed conguration the circulation of major side com-

In Fig. 12 the separation of an equimolar mixture of n-hexane,

n-heptane, and n-octane in a conventional side-draw column and a
dividing wall column is compared. The columns have 50 theoretical
trays. The purity of the distillate and the bottom products is 99.9%.
In the conventional side-draw column the n-heptane concentration
of 82% can be reached and simultaneously a considerable amount
of entropy of mixing is generated on the feed plate. In a dividing
wall column the formation of entropy of mixing on the feed plate
is avoided and n-heptane concentration of 98% in the side product
is reached with the same heat input. A similar case is shown in
Fig. 13 of the paper of Kolbe and Wenzel [13] for a revamp project
of a distillation column for processing pyrolysis gasoline at Ruhr
Oel, where the purity of the benzene in the side-draw could be
increased signicantly through the implementation of a dividing
wall column.
2.4. Applications

Fig. 10. Diagonal off-center position of dividing wall for a vapour feeds and/or
vapour side-draws.

The scope of applications of dividing wall columns is very broad.

There are applications with simple purity demands, as for instance
for solvent recovery, but there are also applications for highest electronic grade purity demands, where impurities are specied in the
ppb range. Operating pressures cover a range between 2 mbar and
10 bar.
All kinds of column internals such as structured or random
packings or trays are used. At BASF the diameters of dividing wall
columns are between 0.6 and 4 m. Outside BASF there are some
larger columns. One of these columns has been installed by Linde
at Sasol for the separation of 1-octene and has a height of 64.5 m
and a diameter of 4.5 m (4 m in the top section) and is equipped
with 2-pass sieve trays (Becker et al. [12]). Another construction of
a dividing wall column of Linde for Sasol is 107 m tall with a diameter of 5.2 m (Schultz et al. [14]). A novel application of dividing wall
column at BASF, as illustrated in Fig. 13, is for butadiene production

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N. Asprion, G. Kaibel / Chemical Engineering and Processing 49 (2010) 139146

Fig. 12. Separation of an equimolar mixture of n-hexane, n-heptane, and n-octane in a conventional side-draw column (left) and a dividing wall column (right) with the
same reboiler energy.

in an extractive distillation. Here the column is a combination of a

rectifying section and a side-rectier (like in Fig. 3a). This column is
equipped partially with trays and the dividing wall is in off-center
position. The light product of the extractive column is separated
further using a tray dividing wall column.
Thermally coupled distillation columns are an alternative to
dividing wall columns (see for example Fig. 2f). They offer the same
energy savings as dividing wall columns, as they also avoid the
formation of entropy of mixing on the feed tray. However, investment costs are higher due to the second column shell. An important
advantage of thermally coupled columns is, that they can be operated at different pressures, if each column is equipped with its own
reboiler and condenser (cf. Fig. 2c). This also can be useful for heat
integration.
2.5. Limitations
Although dividing wall columns belong to niche technologies
they are very important. Some application limitations can be listed
below:
In contrast to conventional congurations, where for each column an own pressure range can be chosen, here only one pressure
range is possible. This results in a larger temperature difference
between reboiler and condenser.

Fig. 13. Application of dividing wall columns in BASFs new butadiene extraction
process.

Compared to a conguration with several columns the dividing

wall column results in increased column height. So in cases where
these limitations are essential, thermally coupled columns are an
alternative. They are as energy-efcient as dividing wall columns
but need a higher total investment.
If the condition of a near-ideal behaviour of the mixtures is not
fullled other congurations might be better suited (cf. for example Stichlmair [15]).
If reactions in the sump of the column lead to low boiling components or if high boiling components at the top of the column
will form, the application of a dividing wall column is prohibitive,
since the specied purities might not be reached in the side-draw.
3. Recent advances
The following topics have been investigated recently:
3.1. Dividing wall columns for multicomponent mixtures
Thermally coupled columns and dividing wall columns for four
(and more) component mixtures have been proposed (e.g. Kaibel
[6], Agrawal [4,16], Christiansen et al. [7,8]. One example is shown
in Fig. 14.

Fig. 14. Example for a separation of ve components in a column with three dividing
walls.

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3.2. Reactive distillation in dividing wall columns

As part of the EU project INSERT the reactive distillation in a
dividing column has been investigated experimentally (Sander et
al. [17]). For these investigations the ester hydrolysis of methylacetate for methanol/methylacetate mixtures, one of the typical
systems for reactive distillation with industrial application, has
been investigated. Here a catalytic packing was used. Comparison
of the experimental results with simulated data from an equilibrium stage model and a rate-based approach showed that the use
of an equilibrium stage model is sufcient for the description of
the process (Geiler et al. [18]). Mller and Kenig [19] investigated
transesterication reactions with a non-equilibrium model taking
the heat transfer across the dividing wall into account.
3.3. Control of dividing wall columns
Serra et al. [20] investigated the congurations according to
Fig. 2a, b, d and e. Compared to these congurations the dividing
wall column operated at some non-optimal operating conditions
has the best controllability. Hernndez et al. [21] investigated the
control structure of thermally coupled columns and they have
shown to outperform conventional systems even with conventional loop pairings. The operation of a dividing wall column is a
strongly coupled process. Adrian et al. [22] showed that model predictive control is superior to the use of single loop PI controllers
especially when constraints for operating conditions should be
taken into account. The additional effort to set up the model predictive control is estimated to be three times higher. Niggemann et
al. [23] used a rigorous dynamic model for the test of different control schemes. The model was validated with the help of pilot and
production plant data. The investigations resulted in an effective
temperature control strategy which was conrmed by test runs.

145

be provided exergy analysis can be used. Agrawal and Fidkowski

[10] and Flores et al. [26] used exergy analysis to compare the thermodynamic efciencies for different column congurations. It was
found that fully thermally coupled columns were not always the
most efcient congurations. Suphanit et al. [27] examined the
exergy loss across the wall of dividing wall columns. They investigated where a heat transfer across the wall is benecial in terms of
reduced exergy losses.
3.7. Optimization of Petlyuk arrangements
Gutirrez-Antonio and Briones-Ramrez [28] estimated the
pareto front, i.e. the set of optimal solutions between minimum
reux (i.e. innite number of stages) and minimum number of
stages (i.e. innite reux). For the estimation of the pareto front
they used a genetic algorithm taking constraints into account. The
pareto front includes all compromises of reux and number of
stages, which means one can choose the best compromise between
energy and equipment cost.
4. Conclusions
Dividing wall columns offer signicant advantages with respect
to investment costs and energy consumption. Their use leads to
compact plants and might result in better product qualities and
higher yields due to the reduced thermal stress. Main disadvantages
are the restriction to only one operating pressure, the higher temperature differences and the increased column height. Advances in
the design, control and operability of dividing wall columns have
contributed to a better understanding of dividing wall columns and
will lead to a growing number of applications.
Acknowledgement

3.4. Start-up procedure

Niggemann et al. [24] investigated the dynamic behaviour of
dividing wall columns during start-up. Based on heuristic rules and
optimization results of their dynamic model different start-up and
control strategies were developed and tested. It was possible with
their start-up procedure to reduce start-up time signicantly.
3.5. Dividing wall columns for batch distillation
Schmidt et al. [25] investigated the use of dividing wall columns
for batch distillation. The benets compared with a conventional
batch distillation were:

Lower batch time, i.e. higher capacity

Lower specic energy demand
High product quality
High product yield
Low thermal stress

The investment cost for a batch dividing column is comparable with the conventional design. The operability is more complex,
since the separation has shown to be very sensitive to liquid distribution at the upper end of the dividing wall.
3.6. Use of exergy analysis for dividing wall column
As already mentioned the application of a dividing wall column allows a reduction of the energy demand. Unfortunately for
example in case of the three component mixture the heat has to be
provided at the boiling temperature of the highest boiling component. To account for the temperature levels at which energy has to

Special thanks to Julius Montz GmbH for providing photos of

dividing wall columns.
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