Paper Number: 101d

First-Generation High-Capacity Trays Still Have What It Takes

Vinson C. Smith
Robert J. Miller

UOP LLC
Houston, Texas, U.S.A.

Kevin J. Richardson
Mohamed S. M. Shakur
Nicholas F. Urbanski

UOP LLC
Tonawanda, New York, U.S.A.

Prepared for Presentation at the

AIChE 2002 Annual Meeting
Session #101 - “Distillation Honors Session”
Indianapolis, Indiana, U.S.A.
04 November 2002

Copyright Ó 2002 by UOP LLC

Unpublished

AIChE shall not be responsible for statements

or opinions contained in papers or printed in its publications.

1:14
First-Generation High-Capacity Trays Still Have What It Takes

V.C. Smith and R.J. Miller, UOP LLC, 13105 Northwest Freeway, Suite 600, Houston,
Texas 77040-6312 U.S.A.

K.J. Richardson, M.S.M. Shakur, and N.F. Urbanski, UOP LLC, P.O. Box 986,
Tonawanda, New York 14151-0986 U.S.A.

ABSTRACT

UOP’s Slotted SieveÔ trays have been installed in over 700 columns since their
inception. The Slotted Sieve tray remains applicable in services ranging from cryogenics
to aromatics separations. UOP collected and analyzed operating data from columns
containing these trays. These operating data confirm that Slotted Sieve trays exhibit high
capacities and efficiencies. Moreover, the trays achieved improved performance with
simple downcomer designs coupled with the bubble promoters and the variable-density,
variable-direction slotting first introduced with the Slotted Sieve tray technology. These
Slotted Sieve trays did not employ, nor require, later tray generation enhancements of
downcomer sloping and truncation to reach their exhibited performances. This paper
presents operating data collected from services which employed Slotted Sieve trays.

INTRODUCTION

Excluding cryogenic services, over 575 distillation columns were built or were
revamped with Slotted Sieve trays since 1964. Figures 1 and 2 depict a one-pass and a
two-pass Slotted Sieve tray, respectively.

Figure 1: One-Pass Slotted Sieve Tray Figure 2: Two-Pass Slotted Sieve Tray

Standard one- and two-pass designs account for roughly 85% of these applications. A
unique parallel flow arrangement of the Slotted Sieve tray represents the remaining 15%

2:14
of the referenced columns. Parallel Flow Slotted SieveÔ trays demonstrate the same
capacity of Slotted Sieve trays; moreover, they exhibit tray efficiencies up to 20+%
higher than conventional trays via the parallel-flow (Lewis Case II) efficiency model.
Table 1 presents total Slotted Sieve tray experience through 2001.

Table 1: Slotted Sieve Tray Experience

Total Sales (through 2001) 575

1-Pass Configuration 452
2-Pass Configuration 34
Parallel Flow Configuration 89

Slotted Sieve trays appear in a wide range of applications. Styrene applications

represent the greatest experience with over 120 combined applications. Ethylene-oxide /
ethylene glycol (EO/EG) applications follow with over 115 applications. Nearly forty
alcohol columns (i.e., methanol, ethanol, isopropanol, butanol) contain Slotted Sieve
trays. Other services that employ Slotted Sieve trays include, but are not limited to, acetic
acid, propylene-oxide / styrene monomer (POSM), silanes, and xylenol / cresol. The
following table lists the total application experience of Slotted Sieve trays. Table 3
provides a comprehensive application listing.

Table 2: Slotted Sieve Tray Application Experience

Application Total
Miscellaneous 175
EO / EG 117
Ethylbenzene / Styrene 101
Acids (non Acetic) 27
POSM 24
Acetic Acid 22
Methanol 18
Benzene / Ethylbenzene 18
Butanol / Isopropanol 17
Silanes 14
Vinyl Acetate 13
Xylenol / Cresol 12
Acid Gas 7
Phenol / Cumene 6
Ethanol 4
Total 575

3:14
Table 3: Comprehensive Slotted Sieve Tray Application Experience
Acetic Acid / Water
Acetone / Acetylene
Acetone / Cumene
Acetaldehyde
Acetic Esters
Acrylic Acid
Acrylic Esters
Acrylonitrile
Adiponitrile
Alcohol Residue
Aldehyde Isomers
Alkylbenzene
Aromatics
Benzene / Ethylbenzene
Benzene / Hexanes
Benzene / Toluene
Butane / Isobutane
Butanol Isomers
Butanol / Isopropanol Methylethylstyrene / Acetophenone
Carbonate Contacting
Cellosolve Evaporating
Chlorophenol Isomers
Cholorotoluene Isomers
Cresol / Phenol
Cresol / Xylenol
Crude Oil Distillation
Cumene Hydroperoxide
Cumene / Phenol
Cumene / Styrene Propylene Oxide / Styrene Monomer
Cyclohexane Finishing
Debutanizer
Deethanizer
Demethanizer
Dichlorosilane
Esters
Ethane / Ethene
Ethanol / Methylethyl Ketone
Ethylbenzene Recovery
Ethylbenzene / Styrene
Ethylbenzene / Xylene
Ethylene / Acetone
Ethyleneamines / Water
Ethylene Glycol / Water
Ethylene Oxide Purification
Ethylene Oxide / Ethylene Glycol
Ethylene Recycle
Glacial Acrylic Acid
Glycol Evaporator
Glyoxal Solvent Recovery
Heavy Water
Hydrogen Cyanide / Water
Nitrotoluene Isomers
Isopropanol Recovery
IsoSivÔ Non-Normals Stabilizer
IsoSiv Normals Stabilizer
IsoSiv Prefractionator
IsoSiv Vent Gas Wash
Methanol Refining
Methanol Topping
Methylbenzyl Alcohol
Methylstyrene Isomers
Methylstyrene / Butylbenzene
Mono / Diethyleneglycol
Naphthol Isomers
Nitrochlorobenzene Isomers
Nitroparaffins
Propane / Propene
Propylene Glycols
Propylene Oxide Stripping
Peracetic Acid
Raffinate Stripping
Refined Acrolein
Resin Oil Fractionation
Silanes
Styrene Finishing
Sulfur Dioxide Absorbing
Tall Oil
Tetralin Stripping
Toluene Wash
Trichlorosilane
Vinyl Acetate
Xylene Isomers
4:14
ADVANTAGES

The wide applicability of the Slotted Sieve tray rises from its unique,
groundbreaking design and operational characteristics. Slotted Sieve trays possess the
following advantages over all other conventional and other high capacity trays:

¥ Low tray spacing experience and design expertise.

¥ Shorter and smaller diameter columns.

¥ Fully active bubbling area mitigating vapor cross-flow channeling.

¥ Lower pressure drop per tray.

¥ Uniform residence time distribution ensuring maximum tray efficiency

and predictable scale-up.

¥ Higher efficiency (especially at flow path lengths exceeding 72 inches).

¥ Stable and predictable operation with large flow path lengths permitting
one- or two-pass geometries in very large diameter columns where
conventional pass-type trays require two- to four-passes to reduce
respective flow path lengths.

Slotted Sieve tray advantages over structured and random packing:

¥ Easily accessible for inspection, cleaning, and maintenance.

¥ No scale-up issues with respect to liquid and vapor maldistribution.

¥ Less capital intensive (no redistributors, no chimney trays, less expensive

material, less metal).

¥ Greater flexibility for locating feeds and withdrawal trays.

¥ Better performance at atmospheric pressures.

¥ Easier revamps of existing trayed columns.

¥ Minimal safety concerns, i.e., fire risk.

Since their invention, many of the once unique characteristics of Slotted Sieve
trays became incorporated into modern-day high-capacity pass-type tray designs (i.e.,
push valves, unidirectional slotting, bubble promoters, blowing clamps). Despite the

5:14
appearance of its basic design features in other technologies, several important factors
continue to differentiate the Slotted Sieve tray from its competitors.

Low Tray Spacing Designs

Slotted Sieve trays were originally developed for air separation plants with
spacings typically around 200 mm. With this background, it is not surprising that Slotted
Sieve tray towers in petrochemical plants routinely possess tray spacings of 305 mm or
less in many services. Forty-four percent of all Slotted Sieve tray designs possess tray
spacing less than 400 mm. Reduced tray spacing may permit the substitution of two
columns of conventional design with a single Slotted Sieve tray column. When
transportation, plot space, or construction codes of a large column present a problem, a
shorter column made possible with Slotted Sieve trays becomes the economical and
logistical answer.

Elimination of Vapor Cross-Flow Channeling

The Slotted Sieve tray eliminates the potential for vapor cross-flow channeling.
Kister, et. al., previously discussed this phenomenon1. Vapor proceeds through the froth
via the path of least resistance. The sustained existence of a froth gradient on a
distillation tray initiates vapor cross-flow channeling. Vapor preferentially passes through
the regions of the tray on which the froth gradient approaches its minimum (typically the
tray outlet). Generally, the potential vapor cross-flow channeling increases with
increasing flow path and decreasing tray spacing. Table 4 compares Slotted Sieve tray
designs to the Kister criteria for an acceptable design that avoids vapor cross-flow
channeling2.

Table 4: Comparing Slotted Sieve Tray Designs to Kister Criteria

Service ID TS % FPL Weir

Open TS Loading
(mm) (mm) Area (m2 / s)
Cresol 1,980 300 12.0 4.6 0.018
Methanol 4,120 450 10.9 6.8 0.019
‡
Styrene 8,382 508 11.8 11.1 0.024
‡
Styrene 9,753 533 12.3 12.6 0.020
Styrene ‡ 10,000 500 10.0 20.0 0.017
Kister Criteria for Acceptable Design < 11.0 < 2.5 < 0.014

‡
- Parallel Flow Slotted Sieve tray applications

6:14
 While this table shows that Slotted Sieve tray designs meet or exceed these
criteria, the tray design itself eliminates cross-flow channeling by preventing hydraulic
gradient formation via slots, bubble promoters, and fully active bubbling areas3. The tray
maintains a uniform froth height that eradicates the manifestation of preferential paths for
vapor flow. This results in uniform vapor distribution across the entire tray, even across
very large flow path lengths.

Low Pressure Drop

Slotted Sieve trays still exhibit the lowest pressure drop per tray compared to
other cross-flow type trays on the market. The pressure drop of Slotted Sieve trays may
be up to 50% less than conventional trays in similar services.

Sieve Holes vs. Valves

Slotted Sieve trays remain primarily comprised of sieve holes, where most of the
liquid-vapor contact occurs. This allows the Slotted Sieve tray deck to possess a greater
amount of open area for a given active (bubbling) area than valve trays. The open area on
Slotted Sieve trays is optimized to minimize pressure drop while maintaining tray
stability and a fully active bubbling area. Figure 3 depicts a typical Slotted Sieve tray
deck with 5.0 mm diameter perforations.

Figure 3: Slotted Sieve Tray Deck

Slots vs. Valves

Slots remain the most effective means of pushing liquid across the tray deck.
Figure 4 illustrates the vapor flow from a slot. The variable density and directionality of
the slots effectively propel the liquid / froth eliminating hydraulic gradients, column wall
effects, and stagnant areas. Slotted Sieve trays exhibit superior residence time distribution
compared to valve trays. Valve trays cannot possess the same degree of density variability
without experiencing froth maldistribution across the tray deck. Figure 5 presents the

7:14
variable density and the variable direction of the slots on Slotted Sieve trays. Figure 6
compares froth propagation with and without the uniform distribution initiated with the
variable density, variable direction slotting.

Figure 4: Vapor Flow from a Slot Figure 5: Variable Slot Density on a Deck

Outlet Outlet
Stagnant
Zone

Inlet Inlet
Figure 6: Trays with (Left) and without (Right) Variable
Density / Direction Slotting

High Efficiency

Uniform residence time distribution (RTD), fully active bubbling areas, and
uniform V/L contact time, contribute to the efficiency enhancement of Slotted Sieve
trays. These trays exhibit at least a 10% higher efficiency than other competing products
in larger diameter columns. Figure 7 presents the exhibited efficiency of Slotted Sieve
trays, and the efficiency enhancement realized with variable density and variable
direction slotting. In contrast, valve trays experience poor RTD (and resulting efficiency)

8:14
across the tray decks of large diameter columns because they cannot possess the same
degree of density variability as the slots on Slotted Sieve trays. Higher efficiencies yield
lower internal traffic rates and lower pressure drops for a given separation and charge
rate.

Straight Uniform Slotting Variable Density and Variable Direction Slotting

1.2
Eo Observed / Eo Calculated

1.0

0.8

0.6

0.4
0 2 4 6 8 10
Revamps Column Diameter (m)

Figure 7: Efficiency Effects of Variable Density and Variable Direction Slotting

Simple Downcomer Configuration

Slotted Sieve trays continue to realize their capacity and efficiency characteristics
with conventional, straight downcomers. The performance of the tray does not require
downcomer truncation and extreme downcomer sloping. As such, difficulties with
hydraulic designs as well as mechanical issues of downcomer truncation and sloping do
not detract from the high performance (efficiency, low pressure drop, capacity) of Slotted
Sieve trays.

Extensive Research, Development, and Design Basis

A long history of research and technology development supports the pressure

drop, efficiency and capacity benefits of Slotted Sieve trays. Initial development of the
Slotted Sieve tray technology dates back to the late 1950’s at Union Carbide’s
Tonawanda, New York site. Here research efforts first discovered the benefits of placing

9:14
bubble promoters and vapor directing slots on sieve trays. Large-scale examinations of
variable slotting commenced a decade later. Tray activity and downcomer performance
enhancements followed. This R&D effort resulted in proprietary tray design guidelines
and fundamental correlations for calculating tray froth density, froth height, pressure
drop, stability factor, and downcomer backup.

The study of RTD and subsequent efficiency enhancement moved from the
smaller Tonawanda test columns to the 7,600 mm diameter air-water column located in
Aycliffe, England, in the late 1960’s. Extensive research and analysis by Weiler, Leavitt,
and Bonnet resulted in a semi-empirical procedure for the design of tray slotting to
achieve plug flow across the tray, thereby, realizing the maximum point to plate
efficiency enhancement. Residence time profiles of dye lines lead to the development of
an efficiency enhancement model for Slotted Sieve trays.4 Residence time examinations
with different degrees of slotting and V/L ratios in large diameter columns commenced
and demonstrated exceptional performance5. As in the initial examinations, Slotted Sieve
trays exhibited h’s (an index defined as the ratio of the calculated actual to the calculated
ideal Murphree plate efficiency) near 1.0.

At this stage, the tray development program reached the following milestones in
the evolution of variable direction and variable density slotting:

¥ Dye line testing in air/water simulators demonstrated that uniform

residence time distribution did NOT exist on conventional sieve trays, but
could exist on Slotted Sieve trays.

¥ Development of equations to calculate the relative tray efficiency based on

actual RTD characteristics of sieve trays with and without slots. These
equations predicted that, in some cases, Slotted Sieve trays could achieve
tray efficiencies 35% greater than trays without slots.

The procedure for determining slot density and slot angles remained semi-
empirical. The calculation of slot density and slot angles for new tray designs required
mathematical equations based on conservation of energy and momentum. While
employed by the Linde Division of Union Carbide during the 1980’s, M.J. Lockett
provided major contributions to this effort. He and coworkers recognized that satisfying
the requirements of gradient elimination and uniform RTD required varying slotting
angels and densities in both the axial and transverse directions – a complex two-
dimensional problem. They developed the following equation:

hr = hh + hb + hk - hl = 0

That is, setting the slotting gradient (h l) equal to the frictional gradient (h h) plus the
bubbling gradient (h b) plus the momentum change gradient (h k). The latter gradient
occurs because of the acceleration and deceleration of the liquid – required because the
liquid flow path width varies across the tray. The above equation more accurately appears
in two directions because of the two-dimensional nature of froth flow across the tray.

10:14
Figure 8 presents the two directions of froth flow across a tray deck – parallel and
perpendicular to the axial centerline6.

Downcomer Vy
q
Bubbling Area

Receiving Vx
Pan

Figure 8: Directional Components to Froth Direction on Distillation Tray

The vector sum of these two slotting components yields the applied slotting7. Lockett and
coworkers derived of these vector equations, understood their application in special
situations (such as the tray inlet), and developed computer programs to calculate slot
densities and slot angles. This work, combined with that of Weiler, provided the strong
experimental and theoretical basis for the commercial application of Slotted Sieve trays.

COMMERCIAL APPLICATION

The following tables present operating data of columns containing Slotted Sieve
trays. Table 5 summarizes a methanol refining service in which a one-pass, large flow
path design achieved desired separation and capacity without employing downcomer
truncation or sloping. Table 6 provides lights service data with two-pass, large flow path
length design that maintained the desired separation without the addition of more passes
at the expense of bubbling area. Table 7 shows cresol service data in which a one-pass,
large flow path length design maintained the desired separation at a small tray spacing
(300 mm).

11:14
 Table 5: Methanol Refining Service with 1-Pass Slotted Sieve Trays

Column Diameter (mm) 4,270

Tray Spacing (mm) 400
% Active Area 82.94%
Flow Path Length (mm) 3,070
Volumetric Liquid Rate (m3/s) 0.059
Liquid Density (kg/m3) 755.11
Volumetric Vapor Rate (m3/s) 21.70
Vapor Density (kg/m3) 1.89
Pressure Drop (mm Hg) 6.29
Cb (m/s) 0.091
Cs (m/s) 0.075
Weir Loading (m2/s) 0.0204

Result: Capacity and desired separation achieved with a simple one-pass,

large flow path length tray geometry.

Table 6: Lights Service with 2-Pass Slotted Sieve Trays

Column Diameter (mm) 8,080

Tray Spacing (mm) 508
% Active Area 79.61%
Flow Path Length (mm) 2,927
Volumetric Liquid Rate (m3/s) 0.121
Liquid Density (kg/m3) 852.34
Volumetric Vapor Rate (m3/s) 139.35
Vapor Density (kg/m3) 0.54
Pressure Drop (mm Hg) 4.19
Cb (m/s) 0.087
Cs (m/s) 0.069
% FRI Flood TR-62 93.0%
% FRI Flood TR-112 79.0%
% FRI Flood TR-138 89.2%
Weir Loading (m2/s) 0.0127

Result: Maintained desired separation in large diameter column with a two-pass

tray design – maximizing bubbling area.

12:14
 Table 7: Cresol Service with 1-Pass Slotted Sieve Trays at 300 mm Tray Spacing

Above Feed Below Feed Bottom

Column Diameter (mm) 1,980 1,980 1,980

Tray Spacing (mm) 300 300 300
% Active Area 85.15% 85.15% 85.15%
Flow Path Length (mm) 2,640 2,640 2,640
Volumetric Liquid Rate (m3/s) 0.015 0.018 0.019
Liquid Density (kg/m3) 737.65 738.13 707.21
Volumetric Vapor Rate (m3/s) 2.21 2.26 2.14
Vapor Density (kg/m3) 5.34 5.35 6.29
Pressure Drop (mm Hg) 3.72 4.19 4.34
Cb (m/s) 0.072 0.073 0.077
Cs (m/s) 0.061 0.062 0.066
% FRI Flood TR-62 90.6 97.0 102.6
% FRI Flood TR-112 81.6 86.9 92.4
% FRI Flood TR-138 112.7 121.2 128.8
Weir Loading (m2/s) 0.0118 0.0143 0.0150

Result: Achieved capacity and desired separation at small tray spacing

and with a large flow path length.

FUTURE

UOP Process Technology and Equipment envisions Slotted Sieve trays continuing
in traditional services and expanding into new fields, including, but not limited to
methanol, styrene, POSM, aromatics, acrylonitrile, acetic acid, ethanol, butanol /
butyraldehydes, and refinery applications. Current research and development includes the
development of improved four-pass configurations and downcomer enhancements that
will complement the superior characteristics of the existing Slotted Sieve trays to produce
a superior pass-type tray. A new day has dawned for these first-generation high-capacity
trays.

13:14
REFERENCES

1 “Vapor Cross-Flow Channeling on Sieve Trays: Fact or Myth?” H.Z. Kister and
K.F. Larson, Brown & Root-Braun, and P.E. Madsen, Kuwait Petroleum
(Danmark), Chemical Engineering Progress, November 1992, pp. 86 - 93

2 Ibid.

3 “The ‘Conventional’ High-Capacity Tray” R.J. Miller, K.J. Richardson, M.S.M.

Shakur, and N.F. Urbanski, UOP LLC, 2001 Annual Meeting, American Institute
of Chemical Engineers, Reno, Nevada, 04 – 09 November 2001

4 “Residence Time Distribution and Plate Efficiency on LINDE Slotted Sieve

Trays” D.W. Weiler, F.W. Leavitt, and F.W. Bonnet, Union Carbide Corporation,
68th National Meeting, American Institute of Chemical Engineers, Houston,
Texas, 28 February – 04 March 1971

5 “Flow Hydraulics of Large Diameter Trays” D.W. Weiler, B.L. England, and
W.V. Delnicki, Union Carbide Corporation, 74th National Meeting, American
Institute of Chemical Engineers, New Orleans, Louisiana, 12 – 15 March 1973

6 “The Design and Performance of Parallel Flow Slotted Sieve Trays” D.W. Weiler
and M.J. Lockett, Union Carbide Corporation, I.Chem.E. Symposium Series No.
94, April 1985

7 Ibid.

14:14