Beruflich Dokumente
Kultur Dokumente
2-1
Table 2.1 shown the condition in inlet and outlet streams of distillation column (Dc 3)
Table 2.1: Condition in inlet and outlet streams of distillation column (Dc 3)
Molar Flow Mass Flow Temperature ( C) Pressure(kpa)
Rate (kmol/m3) Rate(kg/m3)
Feed 197.1 32950 294 820
Distillate 132.4 20260 274.2 600
Bottom 64.65 12690 347.2 600
Figure 2.1 shows the condition in inlet and outlet streams of distillation column.
Vn
Distillate,D
Ln
Feed,F
Bottom,B
Figure 2.1 : Condition in inlet and outlet streams of distillation column(Dc 3)
2-2
2.2 Chemical Design of Distillation Column
Before commencing the column design, the two ‘keys’ components between which it is
desired to make the separation must be selected. The light key will be the component to
be kept out of the bottom product. It has small boiling point and more volatile. The
heavy key is the component to be kept out of the top product. It has large boiling point
and less volatility. Specifications will be set on the maximum concentrations of the keys
in the top and bottom products. The keys are known as ‘adjacent keys’ if they are
adjacent in a listing of the components in order of volatility. While ‘split keys’ is where
some other component lies between them in the order; they will usually be adjacent.
In this design purposes, the light key and the heavy key were determined. The
light key in this column is decene (C10H20) whilst the heavy key in the column is
tetradecene (C14H28) which is the product.
Fenske (1932) equation can be used to calculate minimum number of stages required
at total reflux. Bottom and top stream temperature is calculated by the use of Antoine
equation and Roult’s Law in order to get value of average relative volatility. Those
equations are fairly applied for multicomponent systems.
x x
log LK HK
xHK D xLK B
Nm Eqn (2.1)
log a
2-3
xLK,D mol faction of light key in distillate
xHK, D mol fraction of heavy key in distillate
xHK, B mol fraction of heavy key in bottom stream
xLK, B mol fraction of light key in bottom stream
αa Average relative volatility of light key
It is in need to identify the light and heavy key to determine average relative volatility.
Water is needed to recover much at distillate; therefore it is a light key. a can be
determined by knowing top and bottom column temperature.
Trial and error procedure is required to calculate Tdp and Tbp by the use of Antoine
Equation. The temperature must satisfy the following criteria:
Dew point: x y / K 1.0
i i i
In w hich:
Pi
K
P
Pi is saturation pressure at any guess temperatur e that satisfied the criteria.
2-4
Table 2.2 shown the constant values of Antoine Equation for each component
while Table 2.3, Table 2.4 and Table 2.5 shown the variable at top, bottom and feed
column of distillation column.
Since the value of ∑yi /ki is close to 1.0, therefore this temperature is acceptable.
Since the value of ∑kixi is close to 1.0, therefore this temperature is acceptable
2-5
c) Bubble Point calcution (at the feed column)
Temperature = 317.2 C and Operating pressure = 820 kPa
Since the value of ∑kixi is close to 1.0, therefore this temperature is acceptable
The relative volatility, , of two components can be expressed as the ratio of their K
values :
Table 2.6 and Table 2.7 shown relative volatilities at top and bottom of the
distillation column while Table 2.8 shown average relative volatilities at top and bottom
column.
2-6
Bottom Column (bubble point)
Average Velocity;
0.5458 0.9963
Log
0.0009 0.0037
Nm =
log 3.61628
log(163297.4549)
Nm =
log( 3.61628)
Nm = 9.337872
= 10 stages
2-7
2.2.7 Minimum reflux ratio
The value Ө of must lie between the values of the volatility of the light and heavy keys,
and goind by trial and error method.
Therefore,
x,
ii i f =1-1
x,
ii i f =0
x,
ii i f = 3.555828 x0.3668 1.95083x0.3056 1x0.3275
3.555828
1.950832
1
=0
2-8
Table 2.9 exposed the variable to calculate minimum reflux ratio of distillation
column 3.
Component Composition at
Relative volatilities ,αi
distillate,xi,d
Decene(c10h20) LK 0.5458 4.039248
Dodecene(c12h24) 0.4531 2.080708
Tetradecene(c14h28) HK 0.0009 1
i xi , d
= Rm + 1
i
i xi , d
=
4.039248 x0.5458
2.0850708 x0.4531
1x0.0009
= Rm + 1
i 4.039248 1.247742 2.0850708 1.247742 1 1.247742
The operating reflux ratio is normally set between 1.2Rmin and 1.5Rmin. In this case,
1.5Rmin is chosen,
R = 1.3 Rmin
= 1.3(0.896844)
= 1.165897
2-9
From figure Erbar – Maddox correlation relating number of stages to reflux ratio, see
Appendic 2.1
Nm
= 0.54
N
Therefore,
Nm
N
0.54
10
= 19 stages
0.54
Number of stages including reboiler is 19 stages.
A quick estimate of the overall column efficiency can be obtained from correlation given
by O’Connell (1946)
E0 51 32.5 log( a a ) Eqn (2.6)
2-10
Table 2.10 shown values of calculated viscosity for decene, dodecene and tetradecene.
The minimum number of stages is 19, and overall column efficiency is 62.63463 %.
Consider reboiler and condenser as a stage, therefore, number of real stages is:
(19 1)
Number of actual stages = = 28.37697 = 29 stages
0.6243171
2-11
In order to find the feed point location, an estimate can be made by using the Fenske
equation to calculate the number of stages in the rectifying and stripping section
separately, but this requires an estimate of the feed-point temperature. As an
alternative approach is to use the empirical equation given by Kirkbride (1944) as a
matter
N x x b,LK
2
Log r = 0.206 log B f ,HK
Ns D x f ,LK x
d,HK
Eqn (2.7)
Where, Nr = number of stages above the feed, including any partial condenser
Nr
= 1.50897
Ns
Where actual number of stages is 14,
Nr Ns = 29
0.9111Ns + Ns = 29
1.9111 Ns = 29
Ns = 11.55853 = 12
2-12
2.2.9 Column Sizing
An approximation of column size started once the number of real stages is known. This
procedure includes plate spacing and column diameter.
a) Plate spacing
The overall height of the column will depend on the plate spacing. Plate spacing range
from 0.5 to 1.0 m is normally used. Its spacing depends on column diameter and
operating condition.
b) Column diameter
The principal factor that determines the column diameter is the vapor flow rate. The
equation given below, which is based on the well-known Souders and Brown equation,
Lowenstein (1961), can be used to estimate the maximum allowable superficial vapor
velocity, and hence the column area and diameter:
1/ 2
( L V
uv (0.1710l t 0.27lt 0.047)
2
V Eqn (2.8)
Where, u v = maximum allowable vapor velocity, based on the gross (total)
Column cross-sectional area, m/s
l t =plate spacing, (range 0.5 m – 1.0m)
4 Vw
Dc =
v u v
c) Column area
Column area can be calculated using equation:
Dc 2
Area
4
Where Dc = Column diameter,m2
2-13
2.2.10 Flooding velocity
The flooding condition fixes the upper limit of vapour velocity. A high vapour velocity is
needed for high plate effiencies and the velocity will normally be between to 70 – 90 %
of that cause the flooding.
For this design, the value is between 80 -85% of the dlooding velocity should be used
(Sinnot 2006)
Flooding velocity can be estimated from the correlation given by Fair (1961):
ρL ρV
U f Ki Eqn (2.9)
ρV
where, Uf = flooding vapour velocity, m/s, based on the net column cross-sectional
area
Ki = a constant obtain from figure 11.27
LW V
FLV Eqn (2.10)
VW L
2-14
2.2.11 Calculation for density
a) Top product
Liquid density,ρl
ρL = 516.1kg/m3
Table 2.11 shown values of vapour density for all components at top product of
distillation column.
Mw Tstp Pop
Vapour density, ρv= x x
Vstp Top Pstp Eqn (2.11)
= 20.39423 kg/m3
2-15
b) Bottom product
Liquid density,ρl
ρL = 477.9kg/m3
Table 2.12 shown values of vapour density for all components at bottom product of
distillation column.
Mw Tstp Pop
Vapour density, ρv=
Vstp Top Pstp
= 23.09168 kg/m3
2-16
2.2.12 Calculation for Relative Molar Mass (RMM)
Table 2.13 shown molecular weight and mole fractions for every component at top,
bottom and feed column of distillation column.
Table 2.13: Molecular weight and mole fractions for each component
Molecular Feed Mol Top (D) mol Bottom (B) mol
Component
Weight, MW Fraction, XF Fraction, XD Fraction, XB
Decene(c10h20)
140 0.3668 0.5458 0
Dodecene(c12h24)
168 0.3056 0.4531 0.0037
Tetradecene(c14h28)
196 0.3275 0.0009 0.9963
1.0000 1.0000 1.0000
Hence, after calculations are made, values of RMM at feed, top and bottom
column is shown at Table 2.14.
2-17
2.2.13 Maximum allowable vapour density
Therefore,
1/ 2
( L V
uv (0.1710l 0.27lt 0.047)
2
Top : t
V
516.1 20.39423 1/2
= ( - 0.171 x 0.52+0.27 x 0.5 – 0.047)( )
20.39423
= 0.22564 m/s
1/ 2
( L V
uv (0.1710l t 0.27lt 0.047)
2
Bottom:
V
477.9 23.09168 1/2
= ( - 0.171 x 0.52+0.27 x 0.5 – 0.047)( )
23.09168
= 0.200819m/s
= 5.616305
= 3.517973
2-18
The liquid- vapour flow factor, FLV is given by :
LW V
FLV Eqn (2.12)
VW L
Therefore,
FLV top
3.51797 20.39423
FLV x 0.123164
5.61263 516.1
FLV bottom
3.51797 23.09168
FLV x 0.13769
5.61263 477.9
From the Figure flooding velocity, the value of top and bottom for Ki can be
determined, see Appendic 2.2
Therefore, at spacing, II = 0.5 m , for FLV(top) = 0.123164, the value of Ki = 0.08 while
for FLV(bottom) = 0. 13769, the value of Ki =0.07
516.1 20.39423
Top Uf = 0.08 = 0.398922 m/s
20.39423
477.9 23.09168
Bottom Uf = 0.07 = 0.310659 m/s
23.09168
For design, a value of 80 to 85 per cent of the flooding velocity should be used.
2-19
2.2.15 Maximum volumetric flow-rate
To operating reflux ratio is normally set between 1.2Rmin and 1.5Rmin. for this case,
1.3Rmin is chosen.
R = 1.3 Rmin
= 1.3(0.896844)
= 1.165897
Vm (RMM )
Maximum volumetric flow-rate =
V
L n = Vn D
= (186.7648 – 132.4) kmol/h
= 154.3648 kmol/h
2-20
Where: F = feed molar flowrate
Hence; Lm = 154.3648 + 197.31
= 351.4648 kmol/h
V m ( RMM ) 279.3942(195.8964)
Bottom = = = 0.67588 m3/s
V 23.09168 x3600
volumetric flowrate
Net required, An=
flooding velocity
0.609747
Top = = 1.649818 m2
0.352238
0.67588
Bottom = = 2.371148 m2
0.277669
2-21
2.2.17 Column cross-sectioned area
Dc 2
Area
4 Eqn (2.14)
As first trial, take downcomer area,A d as 12% of total clolum cross-sectional area.
Therefore, downcomer Area,Ad = 0.12Ac
An = Ac – Ad
An = Ac – 0.12Ad
An = (1-0.12)Ac
An = 0.88Ac
An
Therefore, Ac 0.88
4
1.649818
Top = =2.043432m2
0.88
2.371148
Bottom = =2.908599m2
0.88
Top = 0.12Ac
= 0.12 (1.874793)
= 0.245212 m2
Bottom = 0.12Ac
= 0.12 (2.694486)
= 0.349032m2
2-22
2.2.18 Column diameter
4 Ac
Dc =
v
Eqn (2.15)
4(2.14343)
Top = = 1.612679 m
4(2.90859)
Bottom = = 1.92402 m
L m (RMM )
Maximum volumetric liquid rate =
L Eqn (2.16)
351.4648kmol / h(195.8964)kmol / h 1h
= x
477.9kg / m
3
3600s
= 0.040019 m3/s
2-23
2.2.20 Weir Dimensions
a) Weir Length
Ad 0.349032
x 100% = x 100% = 12%
AC 2.908599
From figure relation between downcomer area and weir length, see Appendix 2.6
Iw
= 0.75
Dc
Iw = 0.75 x 1.92402
= 1.443015 m
Area of 1 hole,
dh 2 (0.005 ) 2
A lh = = =1.963 x 10-5 m2
4 4
2-24
Number of holes per plate,
Ah 0.221054
Nh = =11253.63 holes (approximately 10254 holes)
A lh 1.963x10 5
The height of the liquid crest over the weir can be estimated using the Francis weir
formula. For a segmental down comer this can be written as:
2/3
L
h ow = 750 w
l (l w )
Where, lW = weir length
Lw = liquid flow rate, kg/s
L =liquid density
2/3
19.12519kg / s
Maximum h ow = 750 3
= 68.71631 mm liquid
477.9kg / m (1.443015 m)
2/3
13.38763kg / s
Minimum h ow = 750 3
= 54.17412 mm liquid
477.9kg / m (1.443015m)
The lower limit of the operating range occurs when liquid leakage through the plate
holes becomes excessive is known as weep point. The vapor velocity at the weep point
is the minimum value for stable operation. Minimum vapor velocity through the holes
based on the holes area can be calculated using Eduljee (1959) equation:
K 2 0.9(25.4 dh )
Uh (min)
( v )1/ 2 Eqn (2.17)
Where, Uh =minimum vapor velocity through the holes based on the holes area
dh = hole diameter, mm
K 2 = a constant, dependent on the depth of clear liquid on the plate,
Obtain from figure weep-point correlation, see Appendix 2.5
K 2 0.9(25.4 d h )
U h (min)
( v )1 / 2 Eqn (2.18)
31 0.9(25.4 5)
=
(23.09128) 1 2
= 2.630385m/s
mimmumvaporrate
Actual minimum vapor velocity =
Ah
0.7(0.67588m 3 / s)
=
0.221054 m 2
= 2.14028m/s
2-26
1. Plate pressure drop
The pressure drop through the dry plate can be estimated using expression derived for
flow through orifices:
2
U
h d 51 h v
C o L Eqn (2.19)
C o = orifice coefficient
volumetric flow rate
Uh =
hole area, A h
0.67588 m3 / s
Uh = = 3.057542m/s
0.221054 m2
Ah 0.221054m2
x100% = 10 %
Aa 2.21054m2
So, orifice coefficient value can be obtained from figure discharge coefficient, see
Appendix 2.8
C o = 0.84
Therefore, dry plate drop:
2
2.630385m / s 23.09168kg / m 3
hd 51 3
= 159.7019 mm liquid
0.84 525.9852 kg / m
b) Residual head
Residual head can be calculated using Hunt et al (1955) equation:
12.5x10 3
hr
L
12.5 x103
hr =26.1561mm liquid
477.9
2-27
c) Total pressure drop
Where, h ap is the height of the bottom edge of the apron above the plate.
As this is less than A d , thus equation can be used to calculate the head loss in down
comer hdc
2
L
h dc 166 wd
L A m Eqn (2.20)
Where, h dc = head loss in down comer, mm
A m = either the down comer area Ad or the clearance area under the
2-28
Back-up in the down comer, ( h b ),
Entrainment can be estimated from the correlation given by Fair (1961). The
percentage flooding is given by:
Un actual velocity (based on net area)
% flooding
Uf
3
Uf 0.658394m / s
Un = = = 0.26406 m/s
An 2.559567m2
0.26406m / s
% flooding = x100 = 66.19354%
0.398922m / s
2-29
2.2.23 Perforated area
From figure relation between angle subtended by chord, chord height and chord length,
lw 1.388887mm
At 0.76
Dc 1.851849mm
c = 100
Angle subtended at plate edge by unperforated strips = (180 –99) = 800
2-30
Ah 0.221054
= = 0.114515
Ap 1.93035
From figure Relation between hole area and pitch, see Appendix 2.9
lp
= 2.90 (satisfactory, range normally within 2.5 to 4.0)
dh
Rule of thumb: Add 1.2 m at top of column for vapour phase and 1.8 m for reboiler
return.
2-31
Table 2.15 shows summary of the chemical process design for distillation column
Table 2.1: Summary of the chemical process design for distillation column
Plate Thickness 5 mm
Weir Height, hw 50 mm
2-32
2.3 Mechanical Design of Distillation Column
2-33
2.3.2 Minimum wall thickness
A much thicker wall required at column base to withstand wind and weight load. Allow 2
mm for corrosion; 5mm, 7 mm, and 9 mm.
Thus, for further calculation take t = 10 mm.
2-34
Dm = (1. 92402 + 10 x 10-3m)
= 2.02402m
Hv = 14.5 m
Wv = 240(1.15)(2.02402 x (14.2 + 0.8(2.02402)) 10 x 10-3
Wv = 90.0467 kN
b) Weight of plates
Plate area
D 2
Plate area = = 2.908599m²
4
1.2 is factor fir contacting plates, steel including typical liquid loading in kN/m²
Weight of plate = 1.2 kN/m² x 2.908599= 3.490319kN
Weight of 29 plates = 29 x 490319kN = 101.2192kN
c) Weight of insulation
d) Total weight
2-35
2.3.4 Wind loading
x2
M x Fw Eqn (2.23)
2
14.52
M x 4638.746
2
M x 487.6481kNm
a) Pressure stresses
PD
L = Eqn (2.24)
4t
PD
L =
4t
0.661924.02
L =
410
L = 31.74633N/mm2
2-36
PD
h = Eqn (2.25)
2t
0.66(1924.02)
h=
210
h = 63.49266N/mm2
WV
w = Eqn (2.26)
( Dc t )t
60.0467x103
w =
(1924.02 10)10
w = 0.001482 N/m2
1.481838N/mm2
c) Bending Stresses
M Dc
b = t Eqn (2.27)
IV 2
where M = bending moment at bottom tangent line
IV =
64
D 0
4
Di
4
Eqn (2.28)
Do = DC 2t 1944.02 mm
IV =
64
1944.02 4
1944.024 2.84x1010 mm4
Thus;
487.6481x103 1924.02
b = 10
10
2.84 x10 2
b = 16.68271N/mm2
The resultant longitudinal stress is: z L W b
Z (upwind) = 46.9472N/mm2
Z (downwind) = 13.58178N/mm2
2-37
The greatest difference between the principal stresses will be on the downwind side:
h z 77.07445 N/mm2; much below than design stress
The value of differences between the principal stresses is well below the maximum
allowable design stress.
t
C = 2 x104 Eqn (2.29)
o
D
where ν = 0.3 and E = 193000 N/mm² include a high factor of safety,
10
C = 2 x104 N/mm2
1.94402
C = 1028.796 N/mm2
Maximum stress = σw + σh
= 1.481838 + 16.68271
= 18.16455 N/mm²
The maximum stress is well below the critical buckling stress. Therefore, design is
satisfactory.
2-38
2.3.7 Design for the skirt support
The maximum dead weight load on the skirt will occurs when the vessel is full of liquid.
Approximate weight = xDc ( H V ) x L ( g ) Eqn (2.30)
4
Approximate weight = (1.92402m) 2 (14.5m) x (447.9kg/m 3 ) (9.81)
4
= 197.6694kN
Bending moment at base of skirt = Wind loading x (column height + skirt height)2
2
Bending moment at base of skirt = 4.638746 kN x (14.5 m + 1m)² /2
= 710.3079kNm
2-39
a) Stress analysis of skirt base
σ S (tensile) = σ bs – σ ws
σ S (compressive) = σ bs + σ ws
4M s
bs = Eqn (2.31)
( Ds t s )t s Ds
W
ws = Eqn (2.32)
( Ds t s )t s Ds
197.6694x103
ws (test) =
(1924.02 10)10
=3.252912 N/mm2
2-40
405.7036 x103
ws (operating) =
(1924.02 10)10
= 6.67639 N/mm2
Maximum s (compressive);
bs ws = 30.97771N/mm2
Maximum s (tensile):
bs ws = 21.04841N/mm2
Skirt thickness should be under the combination of wind and dead weight load. The
following design criteria are not exceeded:
fs J sin s = 79 N/mm2.
Therefore,
s (tensile) < fs J sin s
21.0484 N/mm2 < 79 N/mm2.
ts
s (compressive) < 0.125 E sin s
Ds
30.9777N/mm2 < 112.0969N/mm2
Both criteria are satisfied; add 2 mm to allow for corrosion. Hence, thickness = 10 mm.
2-41
2.3.8 Base Rings and Anchor Bolts
1 4M s
Area of bolt, Ab = W (4.56)
Nb fb Db
1 4(385000)
= 208034.2
12(79) 1.6
= 1872.955 mm2
Ab x 4
Bolt root diameter, d = (4.57)
1872.955 x 4
=
= 48.8304 mm
4M s W
Fb = (4.58)
Ds
2
Ds
4 (385000) 208034.2
=
(1.924)
2
(1.924)
= 278.689 kN/m
By assuming that a pressure of 5 N/mm2 is one of the concrete foundation pad, f c
2-42
Fb 1
Minimum width of the base ring, L b = x 3 (4.59)
f c 10
278689
=
5 x 10 3
= 55.7378 mm
With this minimum width, can get actual width
Use M56 bolts (BS 4190:1967) root area = 1120 mm2, Figure 13.30, page 849,
Chemical Engineering Volume 6, 1996.
Actual width required = Lr + ts + 50 (4.60)
= 102 + 20 + 50
= 172 mm
Actual bearing pressure on concrete foundation
Fb
f'c = (4.61)
actual width
278.689
=
172
= 1.6203 N/mm2
0.5
3f
Actual minimum base thickness, tb = Lr c (4.62)
fr
Where , fc= actual bearing pressure on base, N/mm2
fr= allowable design stress in the ring material, typically 140 N/mm 2
3(1.6203)
Therefore, tb = 102
140
= 19.0061 mm
19 mm
Chair dimension for bolt size M42. Skirt to be welded flush with outer diameter of
column shell.
2-43
Table 2.16 shows summarized Results of Mechanical Design
2-44
2.4 References
Carl R. Branan, 1994. Rules of Thumb for Chemical Engineers, Gulf Publishing
Company
Micheal J. Barber, 1985. Handbook of Hose, Pipes, Couplings and Fittings, 1st
Edition, The Trade & Technical Press Limited
2-45
Normans, W. S, 1961. Absorption, Distillation and Cooling Towers, Longmans
Louis Gary Lamit, 1981. Piping Systems: Drafting and Design, Prentice-Hall, Inc.
2-46
Appendices
APPENDIX 2.1
2-47
APPENDIX 2.2
APPENDIX 2.3
2-48
APPENDIX 2.4
APPENDIX 2.5
APPENDIX 2.6
2-49
APPENDIX 2.7
APPENDIX 2.8
2-50
APPENDIX 2.9
2-51
2-52