KIL 2008 / KKEK 2158

Separation Processes 1

3 – Continuous Distillation with Reflux & McCabe-

Thiele Method

Dr. Hanee Farzana Binti Hizaddin

Department of Chemical Engineering
University of Malaya

hanee@um.edu.my

1
Learning outcomes
At the end of this class, you should be able to:
• Explain the purpose of reflux in a distillation process
• Explain the purpose of multiple stage equilibrium separation
• Derive the general operating line equation for multiple stage
equilibrium separation
• Familiarize with McCabe-Thiele method and derivation of related
operating line equations
• Apply the McCabe-Thiele method to determine the theoretical
number of stages
• Estimate the condenser and reboiler duty

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Introduction to Distillation with Reflux
• Comparable to a series of flash-vaporization stages arranged in a
series such that the vapor and liquid products from each stage flow
countercurrent to each other.
• https://youtu.be/M7AL7-44YTc

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Distillation with Reflux (Binary Mixtures)
• Same principle is applied as in simple distillation, but this time involves multiple sequential stages of
vaporization and condensation
• Feed enters somewhere in the middle of the column. The feed can
be in liquid, vapor or a mixture of liquid-vapor phase

• The column is divided into a series of stages (cascades of

equilibrium stages)

Rectification • Liquid flows down the column from stage to stage and contacted
section – vapor is by the vapor flowing upward
enriched by
contact with the • In each stage, vapor and liquid enter, mix and reach equilibrium,
reflux liquid and the vapor and liquid leaving the stage are at equilibrium

• The concentration of the more volatile component (lower boiling

component) is being increased in the vapor from each stage going
upward and decreased in the liquid going downward
Stripping section
– liquid portion • The final vapor product is condensed and a portion of the liquid
of the feed serve is removed whereas the remaining is returned to the column as
as reflux in this reflux and enters the top tray of the column
section
• The liquid leaving the bottom trays enter a reboiler where it is
partially vaporized. The vapor from the reboiler enters the bottom
tray and the remaining liquid is withdrawn as a bottom product
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Derivation of the Operating Line equation
L0 V1 Let the total number of stages = N

1 For a total number of stages N, the overall inlet and outlet are:
Liquid inlet = L0 ; Vapor inlet = VN+1 Rearrange Eq 4 to find yn+1:
L1 V2 Liquid outlet = LN ; Vapor outlet = V1

2 Total overall balance for N stages: 𝐿𝑛 𝑥𝑛 𝑉1 𝑦1 − 𝐿0 𝑥0

𝑦𝑛+1 = +
L2 V3 𝑉𝑛+1 𝑉𝑛+1
L0 + VN+1 = LN + V1 Eq 1

Overall component balance for N stages: The operating line

Ln-1 Vn
L0x0 + VN+1yN+1 = LNxN + V1y1 Eq 2
n • The operating line relates the
Ln Vn+1 For the first n stages, the overall inlet and outlet are: concentration yn+1 in the V stream
Liquid inlet = L0 ; Vapor inlet = Vn+1 with xn in the L stream passing it
Liquid outlet = Ln ; Vapor outlet = V1
• The terms V1, y1, L0 and x0 are
LN-1 VN Total overall balance for the first n stages: constant and usually known or can
be determined from Eqs 1 – 4
N L0 + Vn+1 = Ln + V1 Eq 3
VN+1
LN Overall component balance for the first n stages:

L0x0 + Vn+1yn+1 = Lnxn + V1y1 Eq 4 5

McCabe-Thiele Method
• McCabe and Thiele has developed a mathematical-graphical method to determine the number of
theoretical trays or stages needed for separation of a binary mixture A and B (always refer to A
as the more volatile component in this lecture)

• Main assumptions:
• Both components have equal and constant molar enthalpies of vaporization (latent heats). Lead to constant molal
• Sensible heat, CpΔT, is negligible compared to latent heat. overflow assumption
• Column is insulated (no heat loss on each stage).
• Column pressure is constant (thermodynamics can be done at a single pressure).

McCabe-Thiele Method:

• Rectifying section operating line Determine the number

• Stripping section operating line of theoretical trays and
• Feed condition & the “q” line the feed tray location
Rectification section

Liquid returned to the column

Reflux ratio, R=
Overhead product(distillate)
Stripping section
𝐿
𝑅=
𝐷
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Rectifying Section Operating Line
Total material balance: Component material balance:

𝑉𝑛+1 = 𝐿𝑛 + 𝐷 𝑉𝑛+1 𝑦𝑛+1 = 𝐿𝑛 𝑥𝑛 + 𝐷𝑥𝐷

V1
y1 𝐿𝑛 𝐷
Rearrange to obtain the operating line:
𝑦𝑛+1 = 𝑥𝑛 + 𝑥
𝑉𝑛+1 𝑉𝑛+1 𝐷
Using
𝐿𝑛
L D 𝑅=
1 𝐷
L1 x1 xD xD
y2 𝐿𝑛ൗ 𝐷ൗ
𝐿𝑛 𝐿𝑛 𝑅 𝐷 𝐷 𝐷 1
2 = = 𝐷 = = = =
L2 x2 𝑉𝑛+1 𝐿𝑛 + 𝐷 𝐿𝑛ൗ + 𝐷ൗ 𝑅+1 𝑉𝑛+1 𝐿𝑛 + 𝐷 𝐿𝑛ൗ + 𝐷ൗ 𝑅+1
yn 𝐷 𝐷 𝐷 𝐷
n
Ln xn 𝑅 1
yn+1 V Substitute into the operating line: 𝑦𝑛+1 = 𝑥𝑛 + 𝑥
n +1 n+1
𝑅+1 𝑅+1 𝐷

F
zF

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Stripping Section Operating Line
Total material balance: Component material balance:

F 𝑉𝑚+1 = 𝐿𝑚 − 𝐵 𝑉𝑚+1 𝑦𝑚+1 = 𝐿𝑚 𝑥𝑚 − 𝐵𝑥𝐵

zF

Rearrange to obtain the operating line: 𝐿𝑚 𝐵

𝑦𝑚+1 = 𝑉 𝑥𝑚 − 𝑉 𝑥𝐵
𝑚+1 𝑚+1

m Assume constant molal overflow, 𝐿𝑚 = 𝐿𝑁 = constant and 𝑉𝑚+1 = 𝑉𝑁 = constant

Lm xm Vm+1 ym+1
m+1

yN
N
xN
yB
LN

xN
B
xB

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 q-line and feed condition
• Condition of the feed stream F entering the tower determines the relation between the vapor Vm in the stripping
section and Vn in the rectifying section; as well as between Lm and Ln

• E.g. if the vapor is part liquid and part vapor, the vapor will add to Vm to give Vn

Rectification
section

Stripping
section

Cold liquid feed Saturated liquid Partially vaporized Saturated vapor Superheated vapor
feed feed feed feed

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Feed condition
• In cold liquid feed, the entire
feed streams add to the liquid
flowing down the column • When the feed is
• In addition, some vapor saturated liquid, it is at
condenses to heat the feed to its bubble point
the bubble point • No condensation is
• This makes the liquid flow even required to heat the
greater in the stripping section feed, so 𝑉 = 𝑉ത
and decreases the flow of vapor
to the rectifying section
Saturated liquid feed
Cold liquid feed

Part of the liquid

Feed partly vapor
The entire in the rectifying
 liquid portion
feed section is
of the feed
becomes vaporized to
becomes part of L
part of V cool the feed to
and vapor fraction
a state of
becomes part of V
saturated vapor

Saturated vapor feed Superheated vapor feed

Partially vaporized feed 10
q-line and feed condition
• The condition of the feed can be represented by the quantity q defined as:

heat needed to vaporize 1 mol of feed at entering condition

𝑞=
molar latent heat of vaporization of feed

• HV = enthalpy of the feed at

• If the feed is a mixture of liquid and vapor,
𝐻𝑉 − 𝐻𝐹 dew point
𝑞= 𝑞 is the fraction that is liquid
𝐻𝑉 − 𝐻𝐿 • HF = enthalpy of the feed at
its entrance condition
• The value of 𝑞 for cold-liquid feed:
• HL = enthalpy of the feed at
bubble point / boiling point
𝐶𝑝𝐿 𝑇𝑏 − 𝑇𝐹
𝑞 =1+
𝜆

• Cold liquid feed: 𝑞 > 1 • For superheated vapor:

• Saturated liquid feed (feed at bubble point): 𝑞 = 1
• Partially vaporized feed: 0 < 𝑞 < 1 𝐶𝑝𝑉 𝑇𝐹 − 𝑇𝑑
• Saturated vapor feed (feed at dew point): 𝑞 = 0 𝑞=−
𝜆
• Superheated vapor feed: 𝑞 < 0

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Derivation of the q-line equation
• q can also be defined as the number of moles of saturated liquid produced on the feed plate by each
mole of feed added to the tower
Material balance:
𝐿𝑚 = 𝑞𝐹 + 𝐿𝑛 𝑉𝑛 = 𝑉𝑚 + 1 − 𝑞 𝐹

The point of intersection of the rectifying and stripping operating lines can be
derived by using the component material balance equations, without the tray
subscripts (because the intersection will have the same values of x and y)

𝑉𝑛 𝑦 = 𝐿𝑛 𝑥 + 𝐷𝑥𝐷 𝑉𝑚 𝑦 = 𝐿𝑚 𝑥 − 𝐵𝑥𝐵

Subtracting:

Recall overall component

𝑉𝑚 − 𝑉𝑛 𝑦 = 𝐿𝑚 − 𝐿𝑛 𝑥 − 𝐷𝑥𝐷 + 𝐵𝑥𝐵
material balance over the
whole column: Derive the q-line equation:

𝐹𝑧𝐹 = 𝐷𝑥𝐷 + 𝐵𝑥𝐵 𝑞 𝑧𝐹

𝑦= 𝑥−
𝑞−1 𝑞−1

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Finding theoretical number of stages, feed location …
• To determine the number of
theoretical trays, the rectifying and
stripping operating lines are drawn to
intersect with the q line

• Given the specification of the distillate

product composition xD, start to step
off the tray count from the top at xD

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Theoretical number of stages & feed location
• To determine the number of theoretical
trays, the rectifying and stripping
operating lines are drawn to intersect
with the q line

• Assume total condenser and partial

reboiler is used

• Given the specification of the distillate

product composition xD, start to step off
the tray count from the top at xD

• Feed stage is normally located where

the stripping, rectifying and q lines
a) improper location of feed tray
intersect

• However, engineering judgement is

required to locate the optimum feed
location, taking into account the feed
condition and tray efficiency
b) proper location of feed tray
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Example 2: Rectification of a Benzene-Toluene mixture
A liquid mixture of benzene-toluene is to be distilled in a fractionating tower at 101.3 kPa pressure. The feed of
100 kg mol/h is liquid, containing 45 mol% benzene and 55 mol% toluene, and enters at 327.6 K. A distillate
containing 95 mol% benzene and 5 mol% toluene and a bottoms containing 10 mol% benzene and 90 mol%
toluene are to be obtained. The reflux ratio is 4:1. Calculate:
a) The kg moles per hour distillate and bottoms
b) The number of theoretical trays needed

Average heat capacity of the feed is 159 kJ/kmol.K and the average latent heat is 32099 kJ/kmol. VLE data:

Mole fraction of benzene

Vapor pressure (kPa)
T (K) at 101.325 kPa
Benzene Toluene xA yA
353.3 101.32 1.000 1.000
358.2 116.9 46.0 0.780 0.900
363.2 135.5 54.0 0.581 0.777
368.2 155.7 63.3 0.411 0.632
373.2 179.2 74.3 0.258 0.456
378.2 204.2 86.0 0.130 0.261
383.8 240.0 101.32 0 0 15
Example 2: Solution
• Draw the rectifying operating line starting from x=y=xD=0.95 to the y-intercept when x=0, i.e. (0, 0.19)

• Draw the q-line starting from x=y=xF=0.45 to another point calculated using the q-line equation

• The rectifying operating line and the q line will intercept.

• The stripping operating line is drawn starting at the point x=y=xB=0.10 to the point of intersection between the
rectifying operating line and the q line.

• Start to count the number of stages by stepping off at xD=0.95 until xB=0.10

• The feed location is the stage where one side lies on the rectifying line and one side lies on the stripping line. In
this example, the feed stage is located at stage no. 5

• Note: partial reboiler is an equilibrium stage. Thus, the total number of theoretical stage obtained from the graph
must minus the partial reboiler stage.

• In this example, we obtain a total of 7.6 stages. Thus, there are 6.6 theoretical stage after taking out the reboiler.

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Heating and cooling requirement
• Heat loss from a large insulated column is
relatively small, and the column itself is
essentially adiabatic
• The heat effects of the entire unit are confined
to the condenser and the reboiler
• If the average molal latent heat is λ and the
total sensible heat in the liquid stream is small,
the heat added in the reboiler, q, is Vλ (unit:
Watts or Btu/hour)
• When the feed is liquid at its bubble point
(q=1), the heat supplied in the reboiler is
approximately equal to that removed in the
condenser. This is not true for other values of q.
If saturated steam is used as the heating medium,
the steam required at the reboiler is:
𝑉𝜆
𝑚ሶ 𝑆 =
𝜆𝑆
𝑚ሶ 𝑆 = steam consumption
𝑉 = vapor rate from reboiler
𝜆𝑆 = latent heat of steam
𝜆 = molal latent heat of mixture
If water is used as the cooling medium in the condenser and the
condensate is not subcooled, the cooling water requirement is:
𝑉𝜆
𝑚ሶ 𝑊 =
𝑇2 − 𝑇1 𝑐𝑃𝑊
𝑚ሶ 𝑊 = flow rate of cooling water
𝑇2 − 𝑇1 = temperature rise of cooling water
𝑐𝑃𝑊 = specific heat of cooling water
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Example 3 – McCabe-Thiele Method
A continuous fractionating column is to be designed to separate 30 000 kg/h of a mixture of 40 wt.% benzene and
60 wt.% toluene into an overhead product containing 97 wt.% benzene and a bottom product containing 98 wt.%
toluene. A reflux ratio of 3.5 mol to 1 mol product is to be used. The molal latent heats of benzene and toluene are
7 360 and 7 960 cal/mol, respectively. Benzene and toluene form a nearly ideal system with a relative volatility of
about 2.5. The equilibrium data is given. The feed has a boiling point of 95°C at a pressure of 1 atm.

a) Calculate the moles of overhead product and bottom product per hour

b) Determine the number of ideal plates and the position of the feed plate

i. If the feed is liquid and at its boiling point

ii. If the feed is liquid and at 20°C (specific heat 0.44 cal/g.°C)
iii. If the feed is a mixture of two-thirds vapor and one-third liquid

c) If steam at 20 lbf/in2 (1.36 atm) gauge is used for heating, how much steam is required per hour for each of
the above three cases, neglecting heat losses and assuming the reflux is a saturated liquid? (Hint: use steam
table to get the heat of vaporization of steam at this condition)

d) If cooling water enters the condenser at 25°C and leaves at 40°C, how much cooling water is required, in cubic
meters per hour?

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Example 3 – McCabe-Thiele Method
Equilibrium data:

Mole fraction of benzene

Vapor pressure (kPa)
T (°C) at 101.325 kPa
Benzene Toluene xA yA
80.1 101.32 1.000 1.000
85 116.9 46.0 0.780 0.900
90 135.5 54.0 0.581 0.777
95 155.7 63.3 0.411 0.632
100 179.2 74.3 0.258 0.456
105 204.2 86.0 0.130 0.261
110.6 240.0 101.32 0 0

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Example 3 – Answers
a) Overhead product: 153.4 kmol/h; Bottom product: 196.6 kmol/h

b) Number of ideal plates and the location of feed plate for each case.

Rectifying operating line: 𝑦 = 0.778𝑥 + 0.216

i. q=1; q line: 𝑥 = 𝑥𝐹 (vertical line)

ii. q=1.37; q line: 𝑦 = 3.70𝑥 − 1.19
iii. q=1/3; q line: 𝑦 = −0.5𝑥 + 0.66

c) Steam required for each case

i. 10 520 kg/h
ii. 12 500 kg/h
iii. 6 960 kg/h

d) Cooling water needed in cubic meters per hour: 367.5 m3/h

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