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US 8,563,788B2 12 RECOVERY OF BUTANOL FROM A MIXTURE OF BUTANOL, WATER, AND AN ORGANIC EXTRACTANT CROSS-REFERENCE TO RELATED APPLICATIONS Thisapplicationclaimsthebene?tofprioritytoUs. Pro visionalPatentApplicationSer.No. 61/263,502,?ledonNov. 23, 2009, the entirety of Which is herein incorporated by reference. FIELD OF THE INVENTION Processes for recovering butanol from a butanol-contain ing organic phase obtained from an extractive fermentation process are provided. Speci?cally, processes for separating butanol from a mixture comprising butanol, Water, a Water immiscibleorganicextractant,andoptionallyanon-condens ablegas,bydistillationanduseofanentrainerareprovided. BACKGROUND OF THE INVENTION Butanol is an important industrial chemical With a variety of applications, such as use as a fuel additive, as a blend component to diesel fuel, as a feedstock chemical in the plasticsindustry,andasafoodgradeextractantinthefoodand ?avor industry. Each year 10 to 12 billion pounds of butanol are produced by petrochemical means. As the projected demand for butanol increases, interest in producing butanol from reneWable resources such as corn, sugar cane, or cellu losicfeedsbyfermentationisexpanding. 20 25 30 solventbeingselectedfromthegroupconsistingofC7toC11 alcohols,C7toCl1carboxylicacids,estersofC7toCl1car boxylicacids,C7toCl1aldehydes,andmixturesthereof,to form a tWo-phase mixture comprising an aqueous phase and abutanol-containingorganicphase. U.S. Provisional PatentApplicationNos. 61/225,659 and 61/225,662,?ledconcurrentlyonJul.15,2009,disclosepro cesses for separating butanol from a mixture comprising butanol, Water, a Water-immiscible organic extractant, and optionally a non-condensable gas. Processes for recovering butanol from a butanol-contain ingextractantphaseobtainedbyinsituproductremovalfrom a fermentation broth continue to be sought. Economical pro cesses for recovering butanol substantially free of Water and of the extractant are desired. Also desired are separation pro cesses Which minimiZe degradation ofthe extractant, as Well as processes Which provide improved ef?ciency for the desiredseparations. SUMMARY OF THE INVENTION The present invention provides a process for separating a butanol and/or isomers thereof, selected from the group con sisting of 1-butanol, 2-butanol, isobutanol, and mixtures thereof, from a feed comprising a Water-immiscible organic extractant,Water,thebutanol,andoptionallyanon-condens able gas. The separation is made through a combination of distillation, decantation, and use of an entrainer. Inoneaspect,thepresentinventionisaprocesscomprising thesteps: a)introducingafeedcomprising: (i)aWater-immiscibleorganicextractant, (i)Water, (i)atleastone isomer ofbutanol, and (iv)optionallyanon-condensablegas into a ?rst distillation column, Wherein the ?rst distilla tioncolumncomprisesastrippingsectionandoptionally a rectifying section at an introduction point above the strippingsection,the?rstdistillationcolumnhavingan operatingtemperatureT1andanoperatingpressureP1at apredeterminedpointinthestrippingsection,Wherein T 1 and P 1 are selected to produce a ?rst bottoms stream and a ?rst vaporous overhead stream, the ?rst bottoms streamcomprisingtheWater-immiscibleorganicextrac tant and Water and being substantially free of butanol, and the ?rst vaporous overhead stream comprising Water,butanol,optionallytheextractant,andoptionally the non-condensable gas; b) introducing a Water-immiscible organic entrainer to at least one appropriate process stream or vessel; c) condensing the ?rst vaporous overhead stream to pro duce a gas phase and recover a ?rst mixed condensate, Wherein the ?rst mixed condensate comprises: (i)anorganicphasecomprisingbutanol,entrainer,and Water; and (i)anaqueousphasecomprisingWaterandbutanol;and Wherein the ?rst mixed condensate comprises suf?cient entrainertoprovidephaseseparationoftheorganicand theaqueousphases; d)introducingatleastaportionoftheaqueousphasetothe ?rstdistillationcolumn; e) introducing a ?rst portion of the organic phase into a second distillation column having at least a stripping section;and f) operating the second distillation column to produce a second bottoms stream comprising butanol and being Inafermentativeprocesstoproducebutanol,insituprod uctremovaladvantageouslyreducesbutanolinhibitionofthe microorganism and improves fermentation rates by control ling butanol concentrations in the fermentation broth. Tech nologies for in situ product removal include stripping, adsorption,pervaporation,membranesolventextraction,and liquid-liquidextraction.Inliquid-liquidextraction,anextrac tantiscontactedWiththefermentationbrothtopartitionthe 40 butanol betWeen the fermentation broth and the extractant phase. The butanol and the extractant are recovered by a separation process, for example by distillation. In the recov ery process, the butanol can also be separated from any Water, non-condensablegas,and/orfermentationby-productsWhich 45 may havebeenremovedfromthefermentationbroththrough use of the extractant. U.S.patentapplicationSer.No. 12/478,389?ledonJun.4, 2009, discloses methods for producing and recovering butanol from a fermentation broth, the methods comprising the step of contacting the fermentation broth With a Water immiscible organic extractant selected from the group con sisting of C12 to C22 fatty alcohols, Cl2 to C22 fatty acids, estersofC l2toC22 fattyacids,C l2toC22 fattyaldehydes, and mixturesthereof,toformatWo-phasemixturecomprisingan aqueousphaseandabutanol-containingorganicphase. 50 55 U.S. Provisional Patent Application Nos. 61/168,640; 61/168,642; and 61/168,645; ?led concurrently on Apr. 13, 2009; and 61/231,697; 61/231,698; and 61/231,699; ?led concurrentlyonAug.6,2009,disclosemethodsforproducing and recovering butanol from a fermentation medium, the methods comprising the step of contacting the fermentation mediumWithaWater-immiscibleorganicextractantcompris inga?rstsolventandasecondsolvent,the?rstsolventbeing selectedfromthegroupconsistingofC12toC22fattyalco 65 hols,Cl2toC22fattyacids,estersofCl2toC22fattyacids,Cl2 toC22fattyaldehydes,andmixturesthereof,andthesecond 35 60PDF Image | RECOVERY OF BUTANOL
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