CHAPTER 6

DESIGN OF STRIPPING COLUMN

DESIGN OF EQUIPMENTS

Before going in details of stripping column design first we see what is stripping and what its industrial uses are.

STRIPPING
Unit operation where one or more components of a liquid stream are removed by being placed in contact with a gas stream that is insoluble in the liquid stream. OR Stripping is a physical separation process where one or more components are removed from a liquid stream by a vapor stream. In industrial applications the liquid and vapor streams can have co-current or countercurrent flows. Stripping is usually carried out in either a packed or tray column.

THEORY
Stripping works on the basis of mass transfer. The idea is to make the conditions favorable for the more volatile component in the liquid phase to transfer to the vapor phase. This involves a gas-liquid interface that the more volatile component must cross.

EQUIPMENT USED FOR STRIPPING

Stripping is mainly conducted in trayed towers (plate columns) and packed columns, and less often in spray towers, bubble columns and centrifugal contactors.

PLATE COLUMN
Packed columns consist of a vertical column with liquid flowing in from the top and flowing out the bottom. The vapor phase enters from the bottom of the column and exits out of the top. Inside of the column are trays or plates. These trays force the liquid to flow back and forth horizontally while forcing the vapor bubbles up through holes in the trays. The purpose of these trays is to increase the amount of contact area between the liquid and vapor phases.

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PACKED COLUMN

DESIGN OF EQUIPMENTS

Packed columns are similar to plate columns in that the liquid and vapor flows enter and exit in the same manner. The difference is that in packed towers there are no trays. Instead, packing is used to increase the contact area between the liquid and vapor phases. There are many different types of packing used and each one its advantages and disadvantages. The gas liquid contact in a packed bed column is continuous, not stage-wise, as in a plate column. The liquid flows down the column over the packing surface and the gas or vapor, counter-currently, up the column. In some gas-absorption columns co-current flow is used. The performance of a packed column is very much dependent on the maintenance of good liquid and gas distribution throughout the packed bed, and this is an important consideration in packed-column design.

CHOICE OF PLATE OR PACKED COLUMN

The choice between a plate and packed column for a particular application can only be made with complete assurance by costing each design. However, this will not always be worthwhile or necessary, and the choice can usually be made on the basis of experience by considering main advantages and disadvantages of each type; which are listed below: 1. Plate columns can be designed to handle a wider range of liquid and gas flowrates than packed columns. 2. Packed columns are not suitable for very low liquid rates. 3. The efficiency of a plate can be predicted with more certainty than the equivalent term for packing (HETP or HTU). 4. Plate columns can be designed with more assurance than packed columns. There is always some doubt that good liquid distribution can be maintained throughout a packed column under all operating conditions, particularly in large columns. 5. It is easier to make provision for cooling in a plate column; coils can be installed on the plates.

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DESIGN OF EQUIPMENTS

6. It is easier to make provision for the withdrawal of side-streams from plate columns. 7. If the liquid causes fouling, or contains solids, it is easier to make provision for cleaning in a plate column; manways can be installed on the plates. With small diameter columns it may be cheaper to use packing and replace the packing when it becomes fouled. 8. For corrosive liquids a packed column will usually be cheaper than the equivalent plate column. 9. The liquid hold-up is appreciably lower in a packed column than a plate column. This can be important when the inventory of toxic or flammable liquids needs t be kept as small as possible for safety reasons. 10. Packed columns are more suitable for handling foaming systems. 11. The pressure drop per equilibrium stage (HETP) can be lower for packing than plates; and packing should be considered for vacuum columns. 12. Packing should always be considered for small diameter columns, say less than 0.6 m, where plates would be difficult to install, and expensive. Packed column is selected for our operation.

TYPES OF PACKING
The principal requirements of a packing are that it should: Provide a large surface area: a high interfacial area between the gas and liquid. Have an open structure: low resistance to gas flow. Promote uniform liquid distribution on the packing surface. Promote uniform vapor gas flow across the column cross-section.

Many diverse types and shapes of packing have been developed to satisfy these requirements. They can be divided into two broad classes: 1. Packings with a regular geometry: such as stacked rings, grids and proprietary structured packings. 2. Random packings: rings, saddles and proprietary shapes, which are dumped into the column and take up a random arrangement.
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DESIGN OF EQUIPMENTS

Grids have an open structure and are used for high gas rates, where low pressure drop is essential; for example, in cooling towers. Random packings and structured packing elements are more commonly used in the process industries.

RANDOM PACKING
The principal types of random packings are shown

Rasching Rings

Pall Rings

Berl Saddles

Intalox Saddles

Super Intalox Saddles

Metal Hypac
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DESIGN OF EQUIPMENTS

Raschig rings are one of the oldest specially manufactured types of random packing, and are still in general use. Pall rings are essentially Raschig rings in which openings have been made by folding strips of the surface into the ring. This increases the free area and improves the liquid distribution characteristics. Berl saddles were developed to give improved liquid distribution compared to Raschig rings. Intalox saddles can be considered to be an improved type of Berl saddle; their shape makes them easier to manufacture than Berl saddles. The Hypac and Super Intalox packings shown in can be considered improved types of Pall ring and Intalox saddle respectively. Ring and saddle packings are available in a variety of materials: ceramics, metals, plastics and carbon. Metal and plastics (polypropylene) rings are more efficient than ceramic rings, as it is possible to make the walls thinner. Raschig rings are cheaper per unit volume than Pall rings or saddles but are less efficient, and the total cost of the column will usually be higher if Raschig rings are specified. For new columns, the choice will normally be between Pall rings and Berl or Intalox saddles. The choice of material will depend on the nature of the fluids and the operating temperature. Ceramic packing will be the first choice for corrosive liquids; but ceramics are unsuitable for use with strong alkalies. Plastic packings are attacked by some organic solvents, and can only be used up to moderate temperatures. So are unsuitable for distillation columns. Where the column operation is likely to be unstable, metal rings should be used, as ceramic packing is easily broken.

PACKING SIZE
In general, the largest size of packing that is suitable for the size of column should be used, up to 50 mm. Small sizes are appreciably more expensive than the larger sizes. Above 50 mm the lower cost per cubic meter does not normally compensate for the lower mass transfer efficiency. Use of too large a size in a small column can cause poor liquid distribution.

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Recommended size ranges are: Column diameter <0.3 m 0.3 to 0.9 m >0.9 m

DESIGN OF EQUIPMENTS

Use packing size <25 mm 25 to 38 mm 50 to 75 mm

STRUCTURED PACKING
The term structured packing refers to packing elements made up from wire mesh or perforated metal sheets. The material is folded and arranged with a regular geometry, to give a high surface area with a high void fraction. A typical example is shown below.

Structured Packing Structured packings are produced by a number of manufacturers. The basic construction and performance of the various proprietary types available are similar. The advantage of structured packings over random packing is their low HETP (typically less than 0.5 m) and low pressure drop (around 100 Pa/m). They are being increasingly used in the following applications: 1. For difficult separations, requiring many stages: such as the separation of isotopes. 2. High vacuum distillation. 3. For column revamps: to increase capacity and reduce reflux ratio requirements. The applications have mainly been in distillation, but structured packings can also be used in absorption; in applications where high efficiency and low pressure
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drop are needed. The cost of structured packings per cubic meter will be significantly higher than that of random packings, but this is offset by their higher efficiency. Selected packing is random because its cheaper and there are no difficult or vacuum separation requirements.

CHOICE OF RANDOM PACKING

Factors to be considered 1. Void fraction 2. Effective surface 3. Packing size 4. Maximum operating temperature 5. Mechanical strength 6. Material selection Packing used here is 0.038m ceramic intalox saddle because 1. One of the most efficient packings 2. Little tendency to nest and block areas of bed 3. Gives a fairly uniform bed 4. Higher flooding point 5. Lower pressure drop

PACKING PROPERTIES
1.5" Nominal size Packing factor F Package density (kg/m3) Free volume (%) Surface area (m2/m3) 0.038mm 170 580 80 180 Specific gravity (g/cm3) Water absorption (%) Acid resistance (%) Max operating temp. 2.3 <0.3 >99.6 1100

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MATERIAL BALANCE
Component Propylene Hydrogen n-Butanal Iso-Butanal CO propane Total 8712.00 Material In 8163 549 10 17 202 1.88 13726.88 315.94 48.64 44.40 14339.44

DESIGN OF EQUIPMENTS

11 201.23 547.27 266.37 8.83 8141.61 43.76 9201.94

19 0.80 3.64 13460.5 307.11 69.98 0.633 13839.50

= Material Out Stream 11 + Stream 19

Stream 10 + Stream 17 =

Total = 23041.44 kg/hr = Total = 23041.44 kg/hr

STRIPPER FEED (17) Mass flow rate= 14339.44kg/hr Molar flow rate= 203.53kgmol/hr Mole Fraction: Propylene: 0.023 n-Butanal: 0.936 iso-Butanal: 0.021 Propane: 0.0049 STRIPPED GAS (11) Mass flow rate=9201.94kg/hr Molar flow rate= 574.1kgmol/hr Mole Fraction: Propylene: 0.0083 Hydrogen: 0.476 CO: 0.506

N-butanal: 0.0064

Product (19)

STRIPPING GAS (10) Hydrogen: 0.0046 Mass flow rate= 8712kg/hr CO: 0.0085 Molar flowrate= 566.04kgmol/hr

Iso-butanal:.0.0021 Mass flow rate= 13839.5 kg/hr Propane: 0.0017 Molar flowrate= 195.57kgmol/hr Mole Fraction:

Mole Fraction: N-Butanal: 0.956 Hydrogen: 0.484 Iso-Butanal: 0.0218 CO: 0.516 Propylene: 0.000097 Propane: Hydrogen: CO: 0.000073 0.0093 0.12

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PROCESS CONDITIONS
Stream Liquid Inlet Liquid Outlet Gas Inlet Gas Outlet Temperature (K) 313 388 483 317

DESIGN OF EQUIPMENTS

Mass Flowrate (kg/hr) 14339.79 13842 8712 9209

Components\Mole fraction Propylene Hydrogen n-Butanal Iso-Butanal CO Propane

10

17

11

19

0.0236 0.4849 0.00463 0.9366 0.02155 0.5150 0.00853 0.00495

0.00834 0.4767 0.00644 0.00021 0.50655 0.00173

0.00009 0.00932 0.9559 0.02180 0.01278 0.00007

DESIGN APPROACH
1. Determining the diameter of column. 2. Determining the HETP of packing 3. Determining Number of transfer units for the required separation. 4. Determining the height of overall transfer units. 5. Determining the total height of column. 6. Determining the flooding velocity. 7. Verifying the pressure drop across the column. 8. Mechanical Design
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DIAMETER OF COLUMN

DESIGN OF EQUIPMENTS

The column diameter is calculated by following formula = . G= Mass flowrate of gas G= Mass flux of gas To find G first find the flow parameter X as followed L= Mass flow rate of liquid stream g = Density of gas l = Density of liquid x = 0.236 Pressure drop range for strippers and absorbers is 147Pa to 490Pa. Pressure drop of 294 Pa/m of a packed bed is selected. Value of gas mass flux G from figure 12 Chapter 1 Rule of thumbs for chemical engineers 3ed.
..

G=0.7 kg/m2 s

Diameter of packed column is 0.603m.

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DESIGN OF EQUIPMENTS

HEIGHT EQUIVALENT OF THEORETICAL PLATE (HETP)

HETP is calculated as

HETP =

Where A= Size of packing = Surface tension of liquid = 38mm = 29.2 mN/m

= Overall viscosity of feed stream = 0.000414 Pa s HETP = 0.0357m

NUMBER OF TRANSFER UNITS (NTU)

Number of transfer units is calculated as followed.

=
Where =L/HG

= 0.0045 = 203 kmol/hr = 566 kmol/hr = 79.52 Pa/mol fraction = 0.0083 = 0.00009 =0

L=Molar liquid flow rate G=Molar gas flow rate H=Henrys Law Constant

x2=Solute contents in liquid inlet stream mol fraction x1=Solute contents in liquid exit stream mol fraction y1=Solute contents in gas at bottom mol fraction

Ntotal= 4.5 ~ 5

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DESIGN OF EQUIPMENTS

HEIGHT OF OVERALL GAS TRANSFER UNIT (HOG)

Height of overall gas transfer unit is calculated as followed. = Hog = 1.45m

COLUMN HEIGHT
Packing height is calculated as followed Htotal Htotal = Hog x Ntotal

= 7.28m

Giving 0.457m allowance for disengagement of vapors at top and at bottom for liquid. Htotal = 8.194 m

FLOODING VELOCITY
Flooding velocity requires the calculation of the superficial velocity that is given as Vog Vog = = G/Ag 5.88m/s

As general rule superficial velocity is 40% to 60% of the flooding velocity. Taking superficial velocity as 60% of the flooding velocity, then the flooding velocity is given as VF = 9.8m/s

CHECK FOR PRESSURE DROP

For pressure drop calculation we required flow factor and gas mass velocity.

Flow factor X is calculated as

X = 2.66
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DESIGN OF EQUIPMENTS

Gas mass velocity is calculated with following formula. Where mv = Mass flow rate of gas stream A = Area of column

m G v A
G = 0.703 kg/m2 s Now the Y ordinate of figure 12 Chapter 1 Rule of thumbs for chemical engineers 3ed is calculated by the given formula.

.
Y = 0.723

Value of pressure drop for this value of Y is 294Pa/m of packing height.

MECHANICAL DESIGN
THICKNESS OF SHELL
Material selection: Stainless Steel 304 Shell thickness is calculated as given below

ts =Thickness of shell p=Design pressure D=Inside diameter f=Design stress J=Joint efficiency c= Corrosion allowance = O.P. 1.1 = 55.265 N/mm2 = 0.602 m = 145 N/mm2 = 85% = 2mm ts = 82mm

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SHELL WEIGHT
Shell weight is calculated as

DESIGN OF EQUIPMENTS

Shell Weight = Volume of shell Density of shell material Shell weight = 12670 kg

HEAD SELECTION AND THICKNESS

2:1 Elliptical head has been selected because it is used for high pressure requirements and its manufacturing is easy as compared to other types. Material of construction is low alloy steel. Thickness of elliptical head is calculated with following formula = Where th =Thickness of head p =Design pressure Cs=Stress concentration factor Rc=Crown Radius F =Design stress J =Joint efficiency C = Corrosion allowance = O.P. 1.1 = 55.25N/mm2 = 1.77 = 0.602m = 240N/mm2 = 85% =2 th = 83 mm + .

HEAD WEIGHT
Weight of elliptical head is calculated as = W = 58kg

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SUPPORT DESIGN

DESIGN OF EQUIPMENTS

Type of support selected is skirt type support for vertical vessels. Material of construction is construction stainless steel SS-301. First we find maximum dead weight of vessel when full of water. Max. Dead weight Weight of column Weight of Packing = 25.5 kN = 202 kN = 2.364 kN

Wind Loading
= Where w= Dynamic wind pressure = 2790N/m2 x= Length of column = 9.11m Ms = 69813 N Take test thickness of support say 220mm. Tensile strength of support = Where Ms = Wind loading Ds = Inside diameter of shell ts = Thickness of support bs= 0.81 N/mm2 Test compressive strength of support () = + +

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Where

DESIGN OF EQUIPMENTS

W= Dead weight of column when full of water ws (test) = 0.044 N/mm2 Operational compressive strength of support () = Where W= Total weight of column ws (operational) = 0.359 N/mm2 Maximum tensile strength of support = () Max s (Tensile) = 770 kPa Maximum compressive strength of support = () Max s (Compressive) = 455 kPa Check for taken thickness of support Following two conditions must be satisfied. 1. () < Where fs= Design stress J= Joint efficiency = 240N/mm2 = 85% +

s=Base angle (normally taken as 90) 0.0226 < 0.770 Condition 1 is satisfied.

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2.

DESIGN OF EQUIPMENTS

E= Young Modulus of elasticity = 11.35 N/mm2 0.455 < 0.518 Condition 2 is satisfied. So thickness of support = 220mm

PACKING SUPPORT
The best design of packing support is one in which gas inlets are provided above the level where the liquid flows from the bed; such as the gas-injection type. These designs have a low pressure drop and no tendency to flooding. They are available in a wide range of sizes and materials: metals, ceramics and plastics.

Gas-injection type packing support

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LIQUID DISTRIBUTER

DESIGN OF EQUIPMENTS

The pan-type construction provides liquid level balance. Vapor passage is provided by circular gas risers as well as around the periphery of the pan.

Pan-type distributer with bottom holes

SPECIFICATION SHEET
Name of equipment Type No. of equipment Type of packing Material of construction Diameter of column Area of column NTU Hog Height of column Weight of shell Pressure drop Stripper Packed column 1 0.038m ceramic Intalox saddles Low alloy steel 950X 0.602m 1.138m2 5 1.45m 9.11m 12671kg 294Pa/m of packing

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