Computer Aided Design Module for

a Binary Distillation Column

K. R. Onifade
Department of Chemical Engineering, Federal University of Technology
Minna, Nigeria

Abstract

A Computer Aided Design (CAD) module was developed for determining some
design parameters for a binary distillation column using the Lewis-Sorrel method and
Visual Basic. The module made use of a data bank containing physical and
thermodynamic properties of 18 substances. A sample design problem was solved using
the module. Results from the module and manual calculations were very close.

Keywords: Binary distillation column, CAD module, CADdc, Lewis-Sorrel method,

microsoft access, visual basic, differential distillation, equilibrium distillation, rectification.

important parameters in binary distillation is

Introduction
The separation of liquid mixture into
their several components is one of the major
operations in chemical/petroleum industries
and distillation is perhaps the most widely used
method of achieving it. Binary distillation is a
unit operation for separating two or more
components in a mixture by distributing them
between a vapour and liquid phase based on the
difference in the volatility of the components.
Three main methods of binary distillation
are used in practice. These are differential
distillation, flash or equilibrium distillation and
rectification. All rely on the basic fact that the
vapour is always richer in the more volatile
component than the liquid from which it is
formed. In rectification, which is the most
important method, part of the vapour is
condensed and returned as liquid to the still. In
the other two methods, the entire vapour is
either removed or it is condensed as a product.
The essential merit of rectification is that it
enables a vapour to be obtained that is
substantially richer in the more volatile
component than the liquid left in the still. This
is achieved by an arrangement known as a
fractionating column, which enables the
successive vaporization and condensation to be
accomplished in one unit. The theory and
equations and correlations for determining
well discussed in many chemical engineering
text books (Coulson and Richardson 1983;
Hengstebeck 1963; Kern 1990; and Treybal
1981).
Two methods are employed in
calculating the design parameters in binary
distillation. They are the Lewis-Sorrel and
McCabe-Thiele methods. The former method
can also be used for calculations in multi-
component distillation to determine the number
of plates and is the basis of modern
computerised methods. The algorithm for
implementing the method is well documented
(Himmeblau 1974; and McCabe et al. 1993). It
shows that the stage-wise calculations use
equilibrium data and mass balance calculations,
which are represented by the operating line
equations.
Modern engineering practice is becoming
largely dependent on computer and information
technology. Computer Aided Design (CAD) is
therefore used in the design, maintenance and
operations of the plants (Oguntoyinbo 1993;
Rooney and Steadman 1980; and Westerberg et
al. 1979). Plants are generally made up of unit
operation equipment, which are similar in
functions and differ only in their duty or
throughput. A design approach that is yielding
positive results is the independent creation of
modules, which can be incorporated into large

1
systems of flowsheeting (Onifade 2000;
Onifade 2001a). The objective of this work is
to create a similar module for a binary
distillation column.
Methodology
Design Method
Lewis-Sorrel’s method was used in
developing the source code. The column was
assumed to operate under the following
conditions.
1. Constant relative volatility.
2. Constant molar overflow.
3. Normal or reasonable temperature and
pressure.
4. A single point feed.
Development of Module
A data bank of the physical and
thermodynamic properties and Antoine
constants of some substances (Carl et al. 1981;
and Perry 1984) was created. The constants
were used to compute the vapour pressure and
the relative volatility across the column.
Coding Language
The design program was developed using
Visual basic because of its advanced features
that are well suited to modular programming.
Two files are used in implementing the procedure.
These are CADbdc.bas and CADbdc.mdb. The
CADbdc.bas is the program for the source
code. The flowchart for this source code is
shown in Fig. 1. It is a menu oriented and user
friendly program. There is an executable form
of CADbdc.bas, Cadbdc.exe, which can be run
from DOS environment.
The program draws data from Cadbdc.mdb
that contains Antoine’s constants, temperature
range, and molecular weight for 18 substances.
These data are used for computing vapour
pressure through Antoine equations (Coulson et
al. 1991; and Sinno tt 1993). The CADbdc is a
random access Microsoft Access file.
Program Run
The steps for running the program are as
follows:
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1. Load the CADbdc into the Visual basic
window, click Start. A title page will be
displayed on the screen showing an
Architectural Design logo of the program.
This will be followed by the screen in
Fig.2.
2. The user will supply the input
specifications in the window with heading
beginning with ‘S/No’.
3. The user will input the two components by
entering their names in windows with
headings ‘Fluid One Properties’ and ‘Fluid
Two Properties’, respectively. Once the
names are entered, the program will pick
their properties from CADbdc. For the test
problem used in this work, the module has
been programmed to input the names of the
two components automatically.
4. The user will click on the window with α
AB (relative volatility). Two options will
be displayed. One allows the user to supply
the value of the relative volatility directly.
The other option asks the program to
calculate the relative volatility.
5. When Step 4 is done, the window with ‘q
value’ will be activated. When clicked, the
user will be provided with five conditions
for determining q. He will be asked to
choose one. The q value will be displayed
automatically in the window.
6. As soon as Step 5 is completed, the
program will automatically calculate the
necessary design parameters. The results of
the module can be seen by clicking on
“Results” at the top of the left window of
Fig. 2.
7. If an optimization is required, the user can
change any of the design specifications to
obtain the corresponding design
parameters.
The module is ended by choosing exit
from the window on the left.
Results and Discussion
The Test Problem
The module was tested using the
following design problem (Coulson et al. 1991).
A continuous fractionating column is to be
designed to separate 30,000 kg/h of a mixture
of 40% benzene and 60% toluene with the
overhead product containing 97% benzene and
bottom product containing 98% toluene.
These percentages are by weight. A
reflux ratio of 3.5 mole to 1 mole of the
overhead product is to be used. The molar
latent heats of benzene and toluene are 7,360
and 7,960 cal/g-mole, respectively. Benzene
and toluene form an ideal system with a
relative volatility of about 2.5. The feed has a
boiling point of 95o 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 20o C
(specific heat capacity of 0.44 cal/go C.
(iii) if the feed is a mixture of two-thirds
vapour and one third liquid.
(c) If steam at 20 lb f/h2 (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?
(d) If cooling water enters the condenser at
25o C and leaves at 40o C, how much
cooling water are required in cubic meters
per hour?
(e) What is the minimum reflux ration for
cases b(i), b(ii), and b(iii)
(f) What is the minimum number of ideal
plates for cases b(i), b(ii), and b(iii)
Results
The module results for the test problem
are shown in Figs. 3 to 5. Fig. 3 represents
the results for questions (a), b(i), c(i), d(i), e
(i) and f(i). Similarly, Fig. 4 represents the
results for questions (a), b(ii), c(ii), d(ii), e(ii)
and f(ii) while Fig. 5 represents the results
for questions (a), b(iii), c(iii), d(iii), e(iii)
and f(iii).
The comparison of the results obtained
from the module and manual calculations is
shown in Tables 1 to 4.
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Discussion of Results
The results for the top (distillate) and
bottom products are the same for each set of
results in Figs. 3, 4, and 5 because the mass
balance which gives rise to these values is not
affected by q, which is dependent on the
condition of feed.
The q values for the feed conditions in b
(i), b(ii) and b(iii) are: 1.0000, 1.3681 and
0.3333, respectively. The equations for
determining the number of plates in the
rectifying section is not affected by q, hence
the number of plates in the rectifying section is
the same in Figs. 3, 4 and 5. However, in the
stripping section, the liquid (Lm) and vapour
flow rates (Vm) are obtained from:
Ym = Vn + F(q – 1) (1)
Lm = Ln + q F (2)
where Ln and Vn are the liquid and vapour
flow rates in the rectifying section and F is the
feed flow rate.
These equations are used in the stage-
wise calculations to determine the number of
plates in the stripping section.
The mass of steam used in the re-boiler
and the minimum reflux ratio (Rm) are
obtained respectively from:
Ms = λ (Vn + F(q – 1) (3)
λs
Rm = XDN – Yq (4)
Yq – Xq
Where λ is the heat of vaporization of
component B, λs is the molar latent heat of
steam, XDN is the mole fraction of component
A in the distillate and Xq, Yq are the co-
ordinates of the point of intersection of the
enriching operating line and the q line.
Equations (1) to (4) are functions of q,
hence different values will give rise to different
results for number of plates in the stripping
section, the mass of steam used in the re-boiler
and the minimum reflux ratio, as shown in Fig.
3 to 5.
The minimum number of plates and the
mass of water used in the condenser are the
same in Figs. 3, 4, and 5 because q does not
feature in the equations used for determining
them.
 There is a noticeable difference in the
number of plates obtained from module and
manual calculations. The stage-wise
calculations are usually sensitive to rounding
off errors. The manual calculations are more
prone to these errors, so the results using this
method are often higher than those from CAD
module, which relies on computer calculations.
This type of difference has been observed in
CAD module for multi-component distillation
column (Onifade 2000), and shell and tube heat
exchanger (Sinnott 1993).
The correlation coefficient for each set of
values obtained using manual calculations and
CADdc range from 0.87 to 1.00. These values
are adequate for engineering design. It is
significant to note that the worst value of 0.87
arises from the comparison of plates in the
stripping section due to reasons adduced above
for stage-wise calculations.The temperature
and vapour pressure profile of each plate are
important parameters for the eventual
mechanical design of the column (Onifade
2001b). Future work on the module will
therefore include the temperature profile of
each plate and the vapour pressure of each
component on the plates.
Conclusion
The Lewis-Sorrel method was used in
developing a CAD module for implementing
the design of binary distillation column. The
module makes use of a databank for properties
(such as enthalpy, specific volumes, density) of
18 substances.
The CAD module was tested with a
design problem. The results obtained from the
module for certain design parameters were
found to agree with theory and close to those
obtained from manual calculations.
References
Carl, L.Y., Ku,Y.L.; and Fang, C.S. 1981.
Chemical Engineering International News,
p.20c. McGraw-Hill, New York, pp.63-65,
153-156.
4
Coulson, J.M.; and Richardson, J.F., 1983.
Chemical Engineering, Volume 6, 2nd ed.,
Pergamon Press, Oxford.
Coulson, J.M.; Richardson, J.F.; Backhurst, J.R.;
and Harker, J.H. 1991. Chemical
Engineering, 2nd ed., Pergammon Press,
Oxford.
Hengstebeck, R.J. 1963. Distillation: Principles
and Design Procedure. Reinhold, New York.
Himmeblau, D.M. 1974. Basic Principles and
Calculations in Chemical Engineering. 6th
ed., Prentice-Hall, Englewood Cliff, NJ.
Kern, D.O. 1990. Process Heat Transfer.
McGraw Hill, New York.
McCabe, W.L. ; Smith, J.C.; and Harriott, P.
1993. Unit Operations of Chemical
Engineering, 5th ed. McGraw-Hill, New
York.
Oguntoyinbo, S. 1993. Computer Aided Design
and Its Applications in Nitel Research and
Development 2(2): 41-44.
Onifade, K.R. 2000. Computer aided design
module for multi-component distillation
column. AU. J.T. 4: 26-38.
Onifade, K.R. 2001a. Computer aided design
module for an absorption column. AU J.T.
5: 13-20.
Onifade, K.R. 2001b. Computer aided design
module for a binary distillation column.
Proc. 3rd Annual Conference of School of
Engineering and Engineering Technology,
Federal University of Technology, Minna,
Nigeria, Oct. 2001.
Perry, J.H. 1984. Chemical Engineers
Handbook, 7th ed. McGraw-Hill, New York.
Rooney, J.; and Steadman, P. 1980. Principles
of Computer Aided Design. Pitman, London.
Sinnott, R.K. 1993. Chemical Engineering,
Vol. 6, 2nd ed. Pergamon Press, Oxford.
Treybal, R.E. 1981. Mass Transfer Operations.
3rd ed. McGraw-Hill, Auckland, New
Zealand.
Westerberg, A.W.; Hutchison, H.P.; Motard,
R. L.; and Winter, P. 1979. Process
Flowsheeting. Cambridge University Press,
Cambridge.
 Start

Specify
Feed components A and B
Feed, bottom and top composition in % weight
Feed rate in % weight
Heat capacities of the feed components
Initial and boiling temperature of the feed
Vapor fraction of the feed
Heat of vaporization of the components

Calculate
Feed, top and bottom product rate in kg/h
Feed, top and bottom composition in moles
Average molecular weight of the feed
Liquid , vapour flow rates, number of theoretical plates in rectifying section

Specify NO Is
Saturated temperature Relative volatility
given?

Call Databank
YES

Calculate Relative volatility Specify Relative volatility

Select appropriate nature of the feed

Calculate
q-value (Heat fraction)
Liquid and vapor flow rates and number of theoretical plates in the rectifying section
Liquid and vapor flow rates and number of theoretical plates in the stripping section
Total number of theoretical in the column
Mass of steam required in the reboiler
Volume of cooling water required in the condenser

Output the Overall result

Stop

Fig. 1. Flowchart for the source code of CADbdc.bas

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 Fig. 2. Screen for inputting design specification

Fig. 3. CADdbc results for the problem b(i), c(i), d(i), e(i), and f(i)

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 Fig. 4. CADdbc results for the problem b(ii), c(ii), d(ii). E(ii), and f(ii)

Fig. 5. CADdbc results for the problem b(iii), c(iii), d(iii), e(iii), and e(iii)

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 Table 1. Solution to test problem (a)

COMPONENTS
Correl.
Benzene Toluene Total Coeff.
F (kg/hr) Manual 154 196 350
FEED CADdbc 153.8461 195.6521 349.4983 1
xF (mole) Manual .44 .56 1
CADdbc .4401 .5598 1 1
D (kg/h) Manual 149.4 3.98978 153.4
DISTILLATE CADdbc 149.2308 3.9130 153.1438 1
xD (mole) Manual .97 .026 1
CADdbc .9744 .0256 1 0.999992
B (kg/h) Manual 4.7184 191.88 196.6
BOTTOM CADdbc 4.6154 191.7391 196.3545 1
PRODUCT
xB (Mole) Manual 0.024 0.9764 1
CADdbc 0.023514 0.9765 1 1

Table 2. Solution to test problem (b)

No of plates Position of feed (Plate)

Cases Manual CADbdc Manual CADbdc
B(i)) 11 8 4 4
B(ii) 10 8 4 4
B(iii) 12 9 4 4
Corr. Coeff. 0.866025 1

Table 3. Solution to test problem (c) and (d)

Mass of steam (kg/h) Volume of Cooling water (m3 /h)

Cases Manual CADbdc Manual CADbdc
b(i)) 10,520 10508 367.68 367.06
b(ii) 12,500 12470 367.68 367.06
b(iii) 6,960 6955 367.68 367.06
Corr. Coeff. 1 1

Table 4. Solution to test problem (e) and (f)

Rm Nm
Cases Manual CADbdc Manual CADbdc
B(i)) 1.43 1.399 7 7
B(ii) 1.25 1.269 7 7
B(iii) 1.84 1.805 7 7
Corr. Coeff. 1 1