Design of Distillation Column

Distillation
Distillation is the common process in distillery plant and process plant in which components separated
from each other by difference of boiling point. Partial vaporization and condensation are the main process
in the distillation
Column (Plate or Packed)
Mass transfer can be carried out in either packed or tray column , These process are quite different
from each other in terms of designing and operation.
The selection criteria discuss below:
Scale, fouling factors, pressure drop, foaming, corrosive systems, heat evolution and liquid holdup are the
factors that depends the system.

Fluid flow movement dependent.

Physical characteristics of column and internal are important factors for system/process.
Batch operation, continuous operation, intermittent distillation and turndown are the factors also depend
on the selection of tray.
Selection of tray type
Most frequently used trays in industrial distillation columns are
 Bubble cap tray
 Sieve tray
 Valve tray
Tray type column is selected
 They are cheap than packing and less weighted. It is easier to handle and install.
 It has low pressure drop
 It has high efficiency.
 Maintenance cost is low.
 Simple to design.
If properly designed, sieve tray gives desired separation.
Distillation column design steps
 Designation of design basis
 Operating conditions
 Determination of equilibrium stages
 Size of the column
 Design of plate
Designation of Design Basis
F 68428.73 kg/hr
B 60328.80 kg/hr
D 8099.91 kg/hr
 Material Input (kg/hr)
H2 1948.29 0.03
CH4 438.98 0.01
C2H6 659.32 0.01
C3H8 1036.55 0.02
C4H10 2339.66 0.03
C5H12 2904.49 0.04
i-C6H14 5358.68 0.08
n-C6H14 765.53 0.01
i-C7H16 16467.70 0.24
n-C7H16 2579.94 0.04
C6H6 18456.02 0.27
C6H5-CH3 13850.91 0.20
C6H11-CH3 1058.44 0.02
C5H9-CH3 562.04 0.01

Bottom Product
Top Product x Kg/hr
C5H12 0.00 150.82
x kg/hr
i-C6H14 0.01 778.24
H2 0.21 1696.93 n-C6H14 0.09 5483.89
CH4 0.05 409.05 i-C7H16 0.04 2630.34
C2H6 0.08 615.59 n-C7H16 0.28 16638.68
C6H6 0.31 18888.95
C3H8 0.12 939.59
C6H5-CH3 0.23 14116.94
C4H10 0.25 2049.28 C6H11-CH3 0.01 561.06
C5H12 0.30 2389.47 C5H9-CH3 0.02 1079.89
C6H14 0.12 971.99 Total 1.00 68428.73

Total 1.00 8099.91

Operating Conditions
Operating Pressure = 5.50 atm
Streams TemperatureoC
Feed 125
Top Stream 80
Bottom stream 200
Determination of Equilibrium Stages
 Equilibrium data at operating conditions
 Determination of minimum reflux ratio
 Determination of minimum number of stages
 Determination of ideal stages
Equilibrium Data at Operating Condition
Components K-Values Relative Volatility
20.70 64.69
H2
16.40 51.25
CH4
5.50 17.19
C2H6
3.20 10.00
C3H8
1.20 0.53
C4H10
0.56 1.75
C5H12
0.32 1.00
i-C6H14
0.13 4.54
n-C6H14
0.08 0.25
i-C7H16
0.18 0.57
n-C7H16
0.10 0.32
C6H6
0.22 0.68
C6H5-CH3
 bubble point 120.50 C
K vapour presure Α αx y αi-θ
20.70 113.85 64.69 0.03 0.59 62.99
16.40 90.20 51.25 0.35 0.11 53.88
5.50 30.25 17.19 0.18 0.06 15.49
3.20 17.60 10.00 0.15 0.05 8.30
1.20 6.60 0.53 0.02 0.04 -1.18
0.56 3.08 1.75 0.07 0.02 0.05
0.32 1.76 1.00 0.08 0.03 -0.70
0.13 0.72 4.54 0.05 0.00 2.84
0.08 0.44 0.25 0.06 0.02 -1.45
0.18 1.00 0.57 0.02 0.01 -1.13
0.10 0.56 0.32 0.09 0.03 -1.38
0.22 1.20 0.68 0.14 0.04 -1.02
0.12 0.63 0.36 0.01 0.00 -1.34
0.38 2.09 1.19 0.01 0.00 -0.51
1.25 1.00

dew p0int 75.80 C

K vapour pressure α y X
15.00 82.50 18.75 0.03 0.00
10.00 55.00 12.50 0.01 0.00
8.50 46.75 10.63 0.01 0.00
3.40 18.70 4.25 0.02 0.00
1.90 10.45 2.38 0.03 0.02
0.66 3.63 0.83 0.04 0.06
0.80 4.40 1.00 0.08 0.10
0.70 3.85 0.88 0.01 0.02
0.90 4.95 1.13 0.24 0.27
0.96 5.26 1.20 0.04 0.04
0.99 5.43 1.23 0.27 0.27
0.78 4.31 0.98 0.20 0.26
0.51 2.81 0.64 0.02 0.03
0.65 3.60 0.82 0.01 0.01
1.09
Minimum Reflux Ratio
Colburn and Underwood have derived equations for estimating the minimum reflux ratio for
estimating minimum reflux ratio
αi x i,d
 α -θ = R min +1
i

We calculate the value of θ from:

αi x i
 α -θ = q-1
i

Where q >1
From this relation
θ = 1.7
Rmin +1 = 2.11
Rmin = 1.11
Optimum Reflux Ratio ranges from (1.2 – 1.5)Rmin.
Reflux ratio taken is= 1.32
Minimum Number of Stages
By using Fenske’s Equation;
 X   X  
ln  LK   HK  
 X HK d  X LK  b 
Nm = 
lnα LK
 0.295   0.0129  
ln     
 0.12 d  0.0025 b 
Nm = 
ln1.20
Nm =14 plates
Number of Ideal Stages
Using Gilliland relationship

N = 33
Actual Number of Stages and Feed Location
Plate Efficiency
Using O’Connell method
Eo = 51-32.5log(μ a αa )
Where;
μa = average viscosity of liquid, mNs/ m2
αa = Relative volatility of light key
μa = 0.1712 m Ns/ m2

So,
Eo = 51-32.5log(0.1712×1.75)
Eo= 85 %
Actual number of stages (N actual)
Nactual = N ideal / Eo
Nactual= 33/0.85
Nactual= 39
Feed location
By, using kirkbridge Equation;
 ND   B   x   x  2 
log   =0.206log      
fHK bLK

 B
N    fLK  dHK  
D x x

ND/NB=e-0.451
ND/NB=0.6369
ND=0.6369NB
Ntotal =ND+NB
39=(0.6369+1)NB
NB = 23.82=24
So feed is entering at 24th plate from bottom.

Dimensions of Column
Molar Flow Rate of Streams
F 68428.73 kg/hr
B 60328.80 kg/hr
D 8099.91 kg/hr

Top Section
Reflux, Lw=R*D
Lw= 10691.88 kg /hr
VW=LW+D
VW=10691.88+8099.91
=18791.79kg/hr
Vapor Flow Rate
In rectifying section, Vn 13736.29 kg /hr
Liquid Flow Rates
In rectifying section, Ln 4435.582 kg /hr
In stripping section, Lm 54271.89 kg /hr
Lm/W 1.23

Physical Conditions
Top Bottom
Vapor Density, kg/m3 8.78 34.36
Liquid density, kg/m3 504.6 796.3
3
Vapor flow rate, m /sec 0.9486 0.1875
Liquid flow rate, m3/sec 0.122 0.102
Vapor & Liquid velocities can be found by using following formulae respectively.

Vm×M.Wavg
Vapor flow rate =
ρ V ×3600

Lm×M.Wavg
Liquid flow rate =
ρ V ×3600

Flooding Velocity
0.5
 L  ρ 
FLV =  n  v 
 Vn  ρ L 
FLV= 0.1036

From figure11.27, Coulson and Richardson, 6th Ed

At 0.40 m spacing , K1=0.040

ρL -ρV
U f = K1
ρV

Uf= 1.05m/s

80-85% of flooding velocity is mostly used.

Chosing 80%.

Vapor velocity baased on net area.

Un=Uf*0.80

Un=0.84m/s
Down comer Area

Ad=0.12Ac

Net area= An=AT-Ad=0.88Ac

Net area=volumetric flow rate of vapors/ vapor velocity based on net area

Qv= Vw/ρv =5.21/21.57=0.24m3/s

Net area required

An=Qv/Uf=0.24/1.05

An=0.228m2

Column Cross sectional Area

An=0.88Ac

Ac=An/0.88=0.228/0.88

Ac=0259m2

Diameter of Column

Dc=√4 ∗ 𝐴𝑐/𝜋

Dc=0.57m

Down comer Area

Ad=012Ac

Ad=0.03m2
Active Area

Aa=Ac-2d

=0.259-2*0.003

Aa=0.20

Hole Area

Hole area is 10% of column area

Ah=0.259m2

Weir Length

(Ad/Ac*100)=11.6

From Graph b/w (Ad/Ac)*100 vs. lw / Dc on page no 573by “Coulson and Richardson’s”, 6th Ed

lw/Dc=0.73

lw=0.41m
Assumptions
Tray thickness (stainless steel plates) = 55 mm
Weir height = 50mm
Whole diameter = 5mm
Dry tray pressure drop
Hole area/column area = 0.1
Tray thickness/hole diameter = 1
Hole velocity (Uh) = vapor flow rate/hole area = 9.97 m/s
Using graph
Discharge co-efficient for vapor flow (Cvo) = 0.85
2
ρ U 
h h =0.186 v  h 
ρ L  C vo 
hh = 0.85 m of liquid
Wet tray drop
hl = β(hw + how)
Where,
hw = Weir height =50mm= 0.051m
how = Liquid height over weir
β = Aeration factor = 0.65
2/3
q
h ov = 0.48  
 lw 
q = 0.29 m3/s
how = 0.37 m3/s
Tray pressure drop = Dry tray drop + Wet tray drop
ht = hh + hl
ht = 1.12 m of liquid
Calculation of height of column
Height of column = H=Height = No. of trays ×tray spacing+0.9+Ls+0.25D
Tray spacing = 0.45 m
Where, 0.9m = height given above top tray to minimize entrainment
Ls = Height in bottom of column for liquid surge capacity and for reboiler return
Ls = 0.06×number of trays+2
Ls = 4.34 m
H = Height of column = 22.93 m
Tray pressure drop
Pressure drop= dry tray drop + wet tray drop
Tray pressure drop
ΔP = ρl ∗ g ∗ ht
ΔP=650.45*9.18*1.12
ΔP = 6711.69 Pa
ΔP = 0.02 psi