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US 8,563,788B2 9 10 Weightpercententrainer.When more entrainerisusedinthe process than the minimal amount su?icient to provide phase separation of the ?rst mixed condensate under the selected operating conditions, the amount of entrainer in stream 300 is proportionately increased, and the Weight percentages of butanol and Water are proportionately decreased. The over head stream includes non-condensable gas that may have been present in the feed. Stream 300 is condensed in a con denser 670 to produce a ?rst mixed condensate stream 350 comprisingcondensedliquidorganicsandcondensedliquid afermentationvessel(notshoWn).Thiscanprovideameans Water. The ?rst mixed condensate stream 350 should com prise su?icient entrainer to provide phase separation of the organicandtheaqueousphases.Stream350alsoincludesany non-condensable gas present in the feed. The condenser 670 may beofanyconventionaldesign. to recycle some ofthe Water from the butanol recovery pro cess back to the extractive fermentation process. HoWever, it is normally preferred to recycle Water to the fermenter via stream 410, in Which the butanol content is loWer. The mixed condensate stream 350 is introduced into a decanter 700 and alloWed to separate into a liquid organic phase and a liquid aqueous phase. The temperature of the decanter is preferably maintained at or beloW about 400 C. to reducetheamountofbutanol,entrainer,andWaterbeing20 stripped out by the non-condensable gas. The liquid organic phase, the lighter liquid phase (the top liquid phase), can includelessthanabout10WeightpercentWater,orfromabout 0.1toabout5WeightpercentWaterandmay furthercomprise lessthanabout0.1WeightpercentofanyextractantWhich25 comes overhead in column 650. The liquid organic phase can also include less than about 70 Weight percent entrainer, or from about 40 to about 50 Weight percent entrainer. When more entrainerisusedintheprocessthantheminimal amount suf?cienttoprovidephaseseparationofthe?rstmixedcon 30 densate under the selected operating conditions, the amount ofentrainerintheliquidorganicphaseisproportionately thedesiredseparation.Column950shouldhaveatleast6 increased, and the Weight percentages of butanol and Water are proportionately decreased. The residual extractant in the organic phase can be minimiZed by use of a recti?cation 35 sectionincolumn650.Theliquidaqueousphaseincludesless than about 30 Weight percent, or from about 3 to about 20 Weightpercentbutanol.Theliquidaqueousphasecaninclude lessthanabout5Weightpercententrainer,orlessthanabout 1Weightpercententrainer.Thedecantermaybeofanycon 40 ventionaldesign. stages including re-boilerand can be Without are-boilerWhen direct steam is injected from the column bottom. A secondportionoftheorganicphase,stream490,is introducedintothe?rstdistillationcolumn 650. Stream 490 may be introduced as re?ux to the column. Introducing stream 490 into column 650 as re?ux Will suppress extractant loss in vaporous stream 300 of column 650. The ratio of stream490overstream470canrangefromabout0.1to50 Weightpercent. Thevaporousoverheadstream210fromtheseconddistil lation column 950 can include up to about 20 Weight percent butanol and about 5 Weight percent Water. Stream 210 can further comprise about 50 to about 90 Weight percent entrainer.When more entrainerisusedintheprocessthanthe minimal amount suf?cient to provide phase separation ofthe ?rst mixed condensate under the selected operating condi When anon-condensablegassuchascarbondioxideis present in the feed, the non-condensable gas is present in stream 300 and in stream 350. The process may furthercom prisethestepofpurgingatleastaportionofthegasphase 45 comprising the non-condensable gas from the process, as shoWn in FIG. 1, in Which purge stream 460 comprising the non-condensable gas is shoWn leaving the decanter 700. Purgestream460canfurthercompriseentrainer.TominimiZe tions,theamountofentrainerinstream210isproportionately theamountofentrainerWhichislostthroughthispurge50 stream, stream 460 can be partially condensed to recover a portionoftheentrainercontainedtherein,andtherecovered entrainer can be returned to the process (not shoWn). In one embodiment, the process can further comprise the step of partiallycondensingthegasphasetorecoveratleastaportion55 of the entrainer and optionally introducing the recovered entrainer to the mixed condensate. increased,andtheWeightpercentagesofbutanolandWater are proportionately decreased. Stream 210 is condensed in a condenser 975 to produce a second condensate stream 250 comprising butanol, Water, and entrainer. The condenser 975 may be ofany conventional design.At leastaportionofthe secondcondensatestream250maybeintroducedintothe ?rst mixed condensate stream, for example by feeding the second condensate steam 250 into decanter 700. The combi nation of the ?rst mixed condensate stream and the second condensate stream should contain suf?cient entrainer to pro videphaseseparationofthecombinationintoliquidorganic andliquidaqueousphases.Any non-condensablegascanbe From the decanter 700, at least a portion of the aqueous phase 480 is introduced to the ?rst distillation column 650. Theaqueousphase480maybeintroducedasre?uxtothe 60 column and Will typically include al of the aqueous phase separatedinthedecanter.Introducingstream480intocolumn purgedaspreviouslydescribedhereinabove. 650loWersthecolumntemperatureandensuresthatWateris present in the bottoms stream. This is advantageous because highercolumntemperaturesmayresultindegradationofthe65 extractant in the column bottoms, particularly in the case Where fermentation byproducts such as organic acids are presentandtheextractantcontainsfunctionalgroups,suchas unsaturated carbon-carbon bonds in the case of oleyl alcohol, or unfermented sugar and starch. Degradation of any sugar and starch should be avoided as it can cause fouling or plug ging in heat exchanger or tray decks. Degradation of the extractant should be avoided as it can cause decreased e?i ciencyintheextractivefermentationprocess. The process may optionally further comprise introducing at least a portion of the aqueous phase from the decanter into Theorganicphase470leavingthedecanterissplitintotWo portions.A ?rstportionoftheorganicphase,stream500,is introduced into a second distillation column 950, Which has a strippingsection,atafeedpointabovethestrippingsection. The stream 500 is distilled to provide a second bottoms stream600comprisingbutanolandasecondvaporousover head stream 210 comprising butanol, Water, and entrainer. The seconddistillationcolumnisoperatedsoastoprovidethe bottoms stream 600 substantiallyfreeofWaterand substan tiallyfreeofentrainer.By “substantiallyfreeofWater”itis meantthatthebottoms600includelessthanabout0.01 WeightpercentWater.By “substantiallyfreeofentrainer”is meant that the bottoms 600 include less than about 0.01 Weight percent entrainer. The distillationcolumn 950 can be any conventional column having atleastafeedinlet,an over headvaporoutlet,abottomsstreamoutlet,aheatingmeans,a stripping section, and a su?icient number of stages to effect Thevaporousoverheadstream210may furthercomprise volatile fermentation byproducts such as acetaldehyde. Optionally,atleastaportionofstream210maybepurged from the process (not shoWn) to remove volatile fermentation byproducts from the butanol recovery process. 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