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    270 Chapter? Distillation of Binary Mixtures §72. MeCabeThiele Graphical Method for Trayed Towers 269 EXAMPLE 7.1 Distillation of a Mixture of Benzene o and Toluene. ——— Four hundred snd itty Homo 204 kino) a mixtre of 60 me ‘enzene (LK) an 40-mol% toluene (HK) is to be separated int a liquid distillate and liquid bottoms product of 9S mo% and $ mol Ihenzens, respostively. Te foe ents the column with w molt pe cent vaporization equal tothe disillat-to-feed ratio. Use the MoCabe-Thiele method to compute, at 1 atm (101.3 KPa) (8) Nin (F) Rosin and (c) umber of equilibrium stages N, for K/Ryin = 13, and the optimal feedstage location, Also, compare the results with, those from a process simulator ask & ped eaeeet setae Solution First ives ate D and B. An overall material balunse on benzene 02 0406 08 iy 0.60(450) — 0.8-+ 0.08 “ Mole faction of benzane inthe guid « igure 7.13 Determination of minimum stages for Example 7.1. Awtatalance gives 450= D+ B ® a Combining () and @) and solving, D = 27: nmol, snd D/F = 0.611, Thus, the mols vaporization of he feed Women, B= 1 soli. Boo Calculate the slope ofthe eine: : vel (O.81 1nd for panialy vaporized fees a be _(P=Ve)_,_Ye zee te Ye W033 i FOF Foe : i From (7.26), oa @ __0aw9 0.4637 elope me gets = = ES (2) In Figure 7.13, where y and « refer to benzene, xy) = 0.98 and sy ~0.05, the minimum stages are stepped ff betwen the ‘equilibrium curve and the 45° line, giving Mae = 6.7 = 82-4 Be os (b) In Figure 7.14, o-fne is draw that has a slope of ~0.637 and passes through the feed composition (- = 060) onthe 45° i. For Rosin an operaing line forthe rectifying section passes Figure 7.14 Determination of minianom reftax for Exar ple 7. through the point x = Xp =0.95 on the 45 line and through the poin of intersection ofthe line and the equilitium curve (= 0.684, x = 0.465), The slope ofthis operating line is 0.55, ‘which from (7-9) equals /(R-+ 1). Therefore, Ryn = 1.2. () The operating ret aio 1.3 Ryag = 1.3(1.22) = 1.59, From (73). thesiripping-sction operating ine slope is & 39 Rei Taye O64 “The 1wo operating lines and the g-tine re shown in Figure “TAS, where the Stippigg-sectioa operating line i drawn pass through the point x —.xy = 0.05 on the 45° line and through te intersection ofthe gine with the rectifying section ‘operating line. The equiltvium stages ate stepped ofl, Gs, ‘reween the retifyimg-setion operating fine andthe euiitium ‘urve, und then between the strpping-sction operating lie and the equilibeium curve, stating from point A (distillate compost tion) and finishing at pon (havens compesice. Fr the opt ral feed stage, the turer from the retlying-estoa operaing line to the stipping-sstion operating line takes plac at point P, giving N = 13.2 equilibrium stags, the Feed going ino stage 7 fromm the top, and N/Nqin = 13.2)6.7 = 1.97. The bovto a TE) Fiqure 7.15 Determination of number of equilibrium stages and fed-staye location for Example 7.1 270 Chapter? Distillation of Binary Mixtures Feed Stage trom Ton $7.3 EXTENSIONS OF THE MCCABE-THIELE METHOD $7.31 Column Operating Pressure Column pressure and condenser type are established by the algorithm shown in Figure 7.16, whieh is formulated 10, achieve, if possible, a reflu-drum pressure, Pp, between 0 and 415 psia (2.86 MPa) at a minimum temperature of 120°F (49°C), corresponding to the use of water as condenser cool: ant, Pressure and temperature limits depend on economic factors, Columas can operate at a pressure higher than 415 pia if itis well below the critical or convergence pressure of, the mixture, To obtain the bottom pressure, « condenser pres- sure drop of O to 2 psi (0 to 14 kPa) and an overall column, pressure drop of 5 psi (33 kPa) may be assumed. When the number of trays is known, more refined computations give ‘Types of condensers are shown in Figure 7.17. A foral con- denser is suitable for reflux-deum pressures to 215 psia (1.48 MPa). A partial condenser is appropriate trom 215 psia to 365 sia (2.52 MPa) but can be used below 215 psia to give a vapor disilate. A maxed condenser can provide both vapor and lig- uid distillates, 4 retrigerant is often used as coolant above 365 Psia when components are difficult wo condense, As illustrated in Example 7.2, a partial condenser provides an additional sage, based on the assumption that liguid reflux leaving the reflux drum isin equilibrium with the vapor distillate, $7.33 Subcooled Reflux Although most distillation columns are designed so that reflux isa saturated (bubble-point) liquid, such is not always the ease, For an operating column with a partial condenser, the reflux isa saturated liquid unless heat losses occur. For & total condenser, however, the reflux is often & subeaoled lige uid if the condenser is not tightly designed, thus resulting in the distillate bubble-point temperature being much higher than the inlet eooling-water temperature, If the condenser ‘restates ocala butols oo], «215 pie 1.40 MPD) Gitar St” Ts to! condenser oF WC | Vege yf 90 p88 Fy 230 pa P2265 psa 5 Cau dowceait |" Eximate] _ [Calelate madbepain treasure rot” | @E2MPOD | Sorome temperature wrortaoey | Usegamel [Pt rn yo tb ie Ti bottoms Choe a efiaerant soso opus Lower pressure ‘iste (286 MPa} recompute mT Figure 7.16 Algorithm for estabistng disillation-colurma pressure and condonsee type 272 Chapter 7 Distillation of Binary Mixtures $73 Extensions ofthe McCabe-Thiele Method 271 Varo: satiate istiate et A ta o outlet pressure is lower than the top tray pressure, the reflux will be subcooled forall three types of condensers. ‘When subcooted reflux enters the top tray it causes some vapor entering the tray to condense, The latent enthalpy of condensation of the vapor provides the sensible enthalpy 10 heat the subcooled reflux tothe bubble point, In that cuse, the internal reflux ratio within the rectifying section of the eal tumn is higher than the external reflux ratio trom the reflux drum. The MeCabe-Thiele construction should be based on fated from the fol the internal reflux ratio, whieh can be est Towing equation, which is derived from energy balance around the top tray fan approximate fegae(vsSeSTarsie) gay where Cy, and SEP ark per moR Ai AT pte Is the degrees of subcooling. The intemal reflux rato replaces R, the extemal refi ratio in (73) Wa conection ft made for subcooled refx, the caleulaed number of equilibrium stages #8 somewhat were tum required. Thus, subsooled refx is beneficial EXAMPLE 7.2 MeCabe-Thiele Method When Using a Partial Condenser. (Ove thousand kinoVh of 30 mol mtexane and 70% n-octane is Contensate J+ sieam Figure 7.21 Kboilers for plant-size distillation columns: (a) ketie-type reboiler, () vertical thermosyphon-type reboiler Jp= condoneate ile lgu tren from Bato sump Bottom Bottoms » For partially vaporized feed and a total condenser, the reboiler duty is less ta the condenser duty, and is given by n= 0-1 ze | (7-36) ing medium foe the reboiler, balance saturated stear is the he: the steumn rate required is given by the ener MQe (737) ‘where m, = mass flow rate of steam, Ms = molecular weight of steam, and AH," = molar enthalpy of vaporization of steam. ‘The cooling water rate forthe condenser is & Mos = — (7-38) wre m= mate no Tat ill water, Cre tre ot of un int the condenser, cise the cost of reboiler scum is usually an onder of iagninide higher than the cost of cooling water the feed is frequently partially vaporized 1o reduce Ox in comparison to Oc. suggested by 36). (6) vertical thermeyyphon-type reboilr, reboiler quid withdrawn from hodem-ray dovsncomer S2ed-firestinednBxehestater than the pressure in the column at the Feed tray. Excess feed pressure is dropped across valve, which may cause the feed to partially vaporize before centering the column, Erosion on feed trays can be a serious problem in column operations, Second-law thermodynamic efficiency is highest if the feed temperature equals the temperature in the column at the feed tray It is best to avoid a subcooled liguid or superheuted vapor by supplying a partilly vaporized feed. This is achieved by preheating the feed with the bottoms product or 48 process stream that has & suitably high temperature, to ensure a reasonable AT driving force for heat transfer and sufficient available enthalpy. Ratio $73.7 OptimukiReffuxies howween the limiting condi- oarsenfagnigimum and oral reflux. Table 7.3, which is adapted trom Peters and Timmerhaus (6). shows that as & inereases, N decreases, column diameter increases. and reboiler steam and condenser eooling-water requirements, inerease. When the annualized fixed investment costs forthe column, condenser, reflux drum, reflux pump, and reboiler sre added to the annual cost of steam and cooling water, an 272 Chapter 7 Distillation of Binary Mixtures $73 Extensions ofthe McCabe-Thiele Method 271 Table 73. yaar wot eaio ABOWAIZGH Gono 8 ralaon Opcaion Annuaied Co ct Reboiler Duty, Condenser Duty, Cooling ‘Total Annualized RfRwin__Actnal N Equipment Water Steam Cost, Sve 100 tnfinite 67 9,510,160 9,416,000 Infinite 17,340 132,900 Infinite hos » 68 9,776,800 9,680,000 44,640 17,820 136,500, 198,960, Me 5h azaiane—otantoo 38400 Rea eason samo 1 71 to.665600——oseao00 ©6480-9410) 20,890 tsa te 73 treroaoo ——ggooo 3864020220 210900 is 4 1 11,998,800 11,880,000 ass40 21.870 224.910 s 1 300188, : 1182000 saggy «388724300180 24 TD ‘optimal reflus ratio of R/Ryyy = 1 is established in Figure 7.22 for the conditions of Table 7.3, Table 7.3 shows that the annual reboiler-steam ost is, almost eight times the condenser cooling-water east. AL the ‘optimal reflux ratio, steam cost is 70% of the total, Because the cost of steam is dominant, the optimal reflux rato is sen- sitive to the steam cost. Ache extreme of zero cost for steam, the optimal R/Raus is shifted from 1,1 (0 1.32. This example assumes that the heat removed by cooling water in the co denser has no value. ‘The accepted range of optimal to minimum reflux is from 1.05 to 1.50, with the lower value applying to a dificult sepa- ration (e.g., a = 1.2), However, because the optimal reflux ratio is broad, for flexibility, columns are often designed for ‘reflux ratios greater than the optimum, §73.8 Large Numbers of Stages ‘The MeCabe—Thiele construction beor gs invigble when relative volatility oF product purities are Such that many $900,000 s2s000|. Total annualized cost eating oats Anns cost, 2 é Anoualized fixed charges “Jane Wale ig 6 te 20 Optima tax alo ate ai, moe aude io clam or Figure 7.22 Optra vet ratio fora epee ‘operation stages must be stepped off. Ir that event, one of the Following five techniques cat be used: L. Use sepurate plots of expanded seales undfor larger «dimensions for stepping off stages at the ends of the yx diagram, e.g. in added plot covering 0.95 0 1 AAs deseribed hy Horvath and Schubert [7] and shown in Figure 7.23, use a plot based on logarithn dinates for the bottoms end of the y-x diagram, while for the distillate end, turn the log-log graph upside down and rotate it 90°, As seen in Figure 7.23, the operating lines become curved and must be plotted from (7-9) and (7-14). The 45° line remains straight fand the equilibrium curve becomes nearly straight at the two ends, ‘Compute the stages at the two ends algebraically in the manner of part (b) of Example 7.2. This is readily done ‘with a spreadsheet, Use a comme ial MeCubeThicle program. Combine the MeCabe-Thiele gruphical construction with the Kremser equations of $5.4 tor the low and/or hhigh ends, where absorption und stripping factors are ‘almost constant. This preferred technique is illuseated, in Example 7.4. EXAMPLE7.A MeCabe—Thiele Method for a Very Sharp Separation, Repeat part (¢) of Example 7.1 for benzene distilate and bottoms purities of 999 and 0,1 molt, respectively, using 2 rex rio oF 1L8R, which is about 20% higher than the minimum reflux of 144, tthe top ofthe solumn, «= 2.52; a the bvtom, ee = 2.26 Solution Figure 7.24 shows the construction for the region x = 0,028 10 (0.956, with stages stepped off in two directions, starting from the ‘eed staze In this reyion, there are seven stages above the feed nd below ora total of 16 including he feed stage, The Kremser ‘equation is used to determin the remaining stages. 272 Chapter 7 Distillation of Binary Mixtures $73 Extensions ofthe McCabe-Thiele Method 271 029 099 Figure 7.23 Use of ky-tog sl coordinates for MeCabs-Thiele oe 90 0a90,) G99 onstruction: (a) hettomsend of * ° column; (distillate end of w column Figure 724 M Cahe-Thiele of Murphree Vapor Efficiency ¥= 0028 10.x= 0956 272 Chapter 7 Distillation of Binary Mixtures required to establish equilibrium on each stage. Hence, con: centration changes are Tess than those predicted by cequilibriur ‘The Murphree vapor efficiency, introduced in §6.5.4, describes tray performance for individual components in either phase and is equal to the change in composition Jivided by the equilibrium-predicted change. When applied to the vapor phase in a manner similar to (6-28): onl (ran) where Ey isthe Murphree vapor eficeney for sage mn -+ is the stage below, and 3 i the composition in the bypo- thetical vapor phase in equilibrium withthe liquid leaving n. ‘The component subscript in 7-41) is dropped because values of Eye equal for two binary components In stepping off sages, the Murphree vapor etiieney die. totes the faction ofthe dance taken fromthe opereting line to the equiv line. This is shown in Figure 7-25 forthe axe of Murphree efficiencies hased on the vapor phase. In Figure 7.256, the Mumphce tay efficiency i based on the Tigud. In effect, the dashed curve for actual exit-phase com postion replaces the thermodynamic equilibrium curve fora Particular set of operating lines. In Figure 7.253, Ew = EF /EG ~0.7 forthe botiom stage. $73.10 and OPeMfultiple Feeds, Sidestreams, ‘The MeCabSt¥arkte method for a single feed and two prod ucts is extended to multiple feed steams and sidesteams by adding one additional operating line for each additional stream, A multiple-feed —gemen is shown in Figure 7.26. In the absence of sidextpeam Lay thit ra ‘ $73 Extensions ofthe McCabe-Thiele Method 271 no effect on the material balance in the section above the uupper-feed point, F;. The section of column between the upper-feed point snd the lower-Feed point, Fy ¢in the abvence of feed Fis represented by an operating Tine of Slope L!/V’, which intersects the rectifying-section operating Tine. A similar argument holds for the stripping section. Hence itis possible o apply the McCabe-Thiele construction shown in Figure 7.274, where feed Fy is a dew-point vapor, While feed F isa bubble-point liquid. Feed F and sidestream Ls of Figure 7.26 are not present, Thus, between the 160, feed points, the molar vapor flow rute is V! = V— Fy and La L + Fy =L+ Fo, Por given xp,2r, 275%», and L/D, the three operating lines in Figure 7.27 are consteueted. ‘A sidestream may be withdrawn from the rect section, the stripping section, or between multiple feed points, as a saturated vapor or saturated liquid, Within, material-balance constrains, 2y and vy ean both be specitied In Figure 7.27, Saturated-liquid sidestream of LK mole fraction xy and molar flow rate Ls is withdrawn from the rec~ tifyimg section above feed F. In the section of stages between the side stream-withdrawal stage and the feed stage, Li =L=Ls, while = V. The MeCab ne the location of the sidestream stage. However, ot located direciy above x the reflux ratio must be varied until it does. For certain distllations, an energy source is introduced directly into Ue base of the column, Open steam, for example, can be used if one of the components is water or if wa form a second liquid phase, thereby reducing the boiling poi as in the steam distillation of fas, where there is no reboiler and heat is supplied by superheated steam. Commonly, the feed contains water, Which is removed as bottoms. In that application, Ox of Figure 7.26 is replaced by a stream of com- position y = 0 (pure steum), which, with 2 = x, becomes point on the operating line, Since these passing streams exist the end of the coluny ‘Thiele construc” irivis With open steam, the baxtoms flow rate = ielieea sine w _F0 7.28 Use of Murphree plate efficiencies in McCabe Thiele constuction 272 Chapter 7 Distillation of Binary Mixtures $73 Extensions ofthe McCabe-Thiele Method 271 is increased by the flow rute of the open steam. The use of Condensote ‘open steam rather than a reboiler for the operating condition ec Fy = Fy Ly = Ois represented graphically in Figure 7.27 we EXAMPLE TS. McCabe-Thice Method for Cotas m Fees with a Sidestream, f Side stream 4 ‘A column equipped with a partial reboier and total condenser, oper fating at steady tate with a satvrated- guid feed, has a liguid side Stream in the rectifying section, Using the MoCabe-Thiele assumptions; (2) derive the two operating lines in the Testifying sec tion; (b) find the point of intersection ofthe operating lines; () find the intersection of the operating Tine between F and Ly with the fggonal; and ¢) show the construction om ay diagram. Reoiler Solution (a) By material balance over Sestion 1 in Figure 7.28, Ve-i3n-u Bottoms = lgtn + Drip. For Seton 2, Vs-2¥9-9 = Us-18e-1 + 138 +Dxo. The 19 operating lines for conditions of constant molar covertiw become Figure 7.26 Complex distillation column with multiple feeds and sidestream, soe \“G |

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