JQP TRAINING MATERIAL FOR MECHANICAL SECTION MAINTENANCE

DEPARTMENT

COLUMNS

Columns & Distillation

Columns

A column is a distillation vessel in which liquid materials are separated from

one to another by utilizing the boiling point difference between the materials.

See blow picture for distillation column.

 JQP TRAINING MATERIAL FOR MECHANICAL SECTION MAINTENANCE
DEPARTMENT

COLUMNS

Distillation
Distillation is defined as a method of separating mixtures based on differences
in their volatilities in a boiling liquid mixture. Distillation is a unit operation, or
a physical separation process, and not a chemical reaction.

See picture above for distillation column.

Air separation unit

An air separation unit (ASU) is a complex of compressors, heat exchangers and
distillation columns in which air is separated into component gases by
distillation at very low temperatures. The component gases are sold and
distributed to customers for a wide variety of industrial, medical and other
specialist applications.

Air is distilled to separate its componentsnotably oxygen, nitrogen, and

argonfor industrial use.

ASU process plant layout as under:

 JQP TRAINING MATERIAL FOR MECHANICAL SECTION MAINTENANCE
DEPARTMENT

COLUMNS

Types of columns:
Sieved Tray Column

Packed Column
JQP TRAINING MATERIAL FOR MECHANICAL SECTION MAINTENANCE
DEPARTMENT

COLUMNS
 JQP TRAINING MATERIAL FOR MECHANICAL SECTION MAINTENANCE
DEPARTMENT

COLUMNS

Distillation column internal parts:

There are two types of different internals used to achieve separation in side air
separation plant distillation columns:

Sieve Trays & plates:

The terms "trays" and "plates" are used interchangeably. There are many types
of tray designs, but the most common ones are :

Bubble cap trays

A bubble cap tray has riser or chimney fitted over each hole, and a cap
that covers the riser. The cap is mounted so that there is a space
between riser and cap to allow the passage of vapour. Vapour rises
through the chimney and is directed downward by the cap, finally
discharging through slots in the cap, and finally bubbling through the
liquid on the tray.
 JQP TRAINING MATERIAL FOR MECHANICAL SECTION MAINTENANCE
DEPARTMENT

COLUMNS

Valve trays
In valve trays, perforations are covered by liftable caps. Vapor flows
lifts the caps, thus self creating a flow area for the passage of vapor.
The lifting cap directs the vapor to flow horizontally into the liquid, thus
providing better mixing than is possible in sieve trays.
JQP TRAINING MATERIAL FOR MECHANICAL SECTION MAINTENANCE
DEPARTMENT

COLUMNS
 JQP TRAINING MATERIAL FOR MECHANICAL SECTION MAINTENANCE
DEPARTMENT

COLUMNS

Sieve trays
Sieve trays are simply metal plates with holes in them. Vapour passes
straight upward through the liquid on the plate. The arrangement,
number and size of the holes are design parameters.
 JQP TRAINING MATERIAL FOR MECHANICAL SECTION MAINTENANCE
DEPARTMENT

COLUMNS

Packing
There has been a move towards the use of structured packing in cryogenic
distillation columns.

The packing used in cryogenic plants is honeycombed sections of light sheet

stainless steel or aluminium

The big advantage of packed columns is their low pressure drop and
consequently a low plant power compared to conventional trayed columns.
Because the advantage of low pressure drop is more critical at lower pressures
it is usually the LP and argon columns that are packed with the HP column
staying as a trayed column.
JQP TRAINING MATERIAL FOR MECHANICAL SECTION MAINTENANCE
DEPARTMENT

COLUMNS
 JQP TRAINING MATERIAL FOR MECHANICAL SECTION MAINTENANCE
DEPARTMENT

COLUMNS

Liquid Distributors:
Liquid distributors are used to give a uniform spread of liquid over the top
surface of the packed bed whilst permitting the passage of vapor through the
distributor.

The quality of liquid distribution is of vital importance and any design and
installation should ensure equal distribution over the whole surface of the
packing.

A distributor is required at every feed and product off take point and in argon
columns between sections of packing.

Two principle types of distributor are used

- chimney type
- channel type

Above each distributor there is a collect header to ensure the liquid is correctly
feed to the distributor
 JQP TRAINING MATERIAL FOR MECHANICAL SECTION MAINTENANCE
DEPARTMENT

COLUMNS

Downflow Reboiler:-
In a downflow reboiler both the HP nitrogen stream and the LP liqujd oxygen
stream run co-currently down the reboiler rather than counter current as in a
standard thermosyphon reboiler.
 JQP TRAINING MATERIAL FOR MECHANICAL SECTION MAINTENANCE
DEPARTMENT

COLUMNS

DownFlowCondenser LOX

- used instead of two-storied or

PGAN
more-storied bath condensers

- no condenser vessel

- LOX-recycle pump for reflux is necessary

PLIN - oxygen pipework is necessary

- fit for ASU's with internal LOX compression

GOX+LOX
- fit for large size ASU's

PLIN - energy saving solution

PGAN Top of
Pressure column
 JQP TRAINING MATERIAL FOR MECHANICAL SECTION MAINTENANCE
DEPARTMENT

COLUMNS

In operation no part of the downflow reboiler is submerged in the LP column

sump.
This means there is a much smaller inventory of liquid in the LP column sump.
Any submergence of the bottom of the down flow reboiler will cause a
reduction in performance and will quickly lead to loss of condensing /
reboiling.
To ensure efficient and safe operation of the downflow rebolier liquid must be
distributed equally across all passages. Liquid from the bottom section of the
column is collected in a header tank (swimming pool) on top of the downflow
reboiler.

This tank carries out two tasks

- it provides sufficient head for the boiling liquid to be driven down the reboiler
- it ensures the liquid is distributed properly across the core.
Oxygen vapour must not be allowed to flow back up the reboiler passages as it
could cause dry boiling and build up of hydrocarbons. To ensure this does not
happen the liquid rate from the reboiler should be at least 10% of the plant air
feed.
In addition there is a fin arrangement at the top of the reboiler known as the
hardway fin. Vapour and gas generated in the reboiler passages cannot pass
through this, only liquid coming down from the swimming pool.

In a downflow reboiler both the HP nitrogen stream and the LP liquid oxygen
stream run co-currently down the reboiler rather than counter current as in a
standard thermosyphon reboiler.
This leads to a closer differential temperature and a smaller reboiler than an
equivalent themosyphon.

In a thermosyphon reboiler the core is submerged in the sump of the LP

column. This leads to the liquid entering the bottom of the reboiler being sub-
cooled. Approx 1/3 of the heat transfer area of a thermosyphon reboiler is
taken up in over-coming this sub-cooling. In a downflow reboiler the liquid
 JQP TRAINING MATERIAL FOR MECHANICAL SECTION MAINTENANCE
DEPARTMENT

COLUMNS

enters the reboiler from the top, almost at its saturation temperature. This
means that the need for de-sub-cooling is small and boiling can start
immediately.