Distillation Column Design

Syed Zaheer Abbas

Distillation:
Process in which a liquid or vapour
mixture of two or more substances
is separated into its component
fractions of desired purity, by the
application and removal of heat
The design of a distillation column can be divided into
the following steps:
Specify the degree of separation required: set product
specifications.
Select the operating conditions: batch or continuous;
operating pressure.
Select the type of contacting device: plates or
packing.
Determine the stage and reflux requirements: the
number of equilibrium stages.
Size the column: diameter, number of real stages.
Design the column internals: plates, distributors,
packing supports.
Mechanical design: vessel and internal fittings.
The separation of liquid
mixtures by distillation
depends on differences in
volatility between the
components. The greater the
relative volatilities, the easier
the separation.
In the section below the feed,
the more volatile
components are stripped
from the liquid and this is
known as the stripping
section. Above the feed, the
concentration of the more
volatile components is
increased and this is called
the enrichment, or more
commonly, the rectifying
section.
Reflux considerations
The reflux ratio, R, is normally defined
as:
R = (flow returned as reflux)/(flow of top
product taken off)

The number of stages required for a
given separation will be dependent on
the reflux ratio used.
Total reflux
Total reflux is the condition when all the
condensate is returned to the column as
reflux: no product is taken off and there
is no feed.
At total reflux the number of stages
required for a given separation is the
minimum at which it is theoretically
possible to achieve the separation.
Minimum reflux
As the reflux ratio is reduced a pinch
point will occur at which the separation
can only be achieved with an infinite
number of stages. This sets the
minimum possible reflux ratio for the
specified separation.
Optimum reflux ratio
Practical reflux ratios will lie somewhere
between the minimum for the specified
separation and total reflux.
For many systems the optimum will lie
between 1.2 to 1.5 times the minimum
reflux ratio.
Flooding and Weeping
Flow weeps through
the holes at low vapor
velocity
Weeping
Liquid cannot get
down the column
at high vapor velocity
Flooding
Feed-point location
The precise location of the feed point
will affect the number of stages
required for a specified separation
and the subsequent operation of the
column. As a general rule, the feed
should enter the column at the point
that gives the best match between the
feed composition (vapor and liquid if
two phases) and the vapor and liquid
streams in the column.
Dew points and bubble points
Dew points and bubble points can be
calculated from a knowledge of the
vapor-liquid equilibrium for the
system. In terms of equilibrium
constants, the bubble point is defined
by the equation:
Choice b/w Tray & Packed Column
Plate column are designed to handle wide range
of liquid flow rates without flooding.
For large column heights, weight of the packed
column is more than plate column.
Man holes will be provided for cleaning in tray
Columns. In packed columns packing must be
removed before cleaning.
When large temperature changes are involved as
in the distillation operations tray column are often
preferred.
Random-Packed Column generally not designed
with the diameter larger than 1.5 m and diameters
of commercial tray column is seldom less than
0.67m
Selection of Trays:
DESIGNING STEPS OF
DISTILLATION COLUMN

Calculation of Minimum number of stages,
Nmin
Calculation of Minimum Reflux Ratio Rm.
Calculation of Actual Reflux Ratio.
Calculation of theoretical number of stages.
Calculation of actual number of stages.
Calculation of diameter of the column.
Calculation of weeping point, entrainment.
Calculation of pressure drop.
Calculation of the height of the column.
Calculation of Minimum no. of
Plates:
The minimum no. of stages Nmin is
obtained from Fenske equation which is,

N
min
= LN[(x
LK
/x
HK
)
D
(x
HK
/x
LK
)
B
]
LN (
LK
/
HK
)
average

Theoretical no. of Plates:
(

|
.
|

\
|
+

=
+

566 . 0
min min
1
1 75 . 0
1 R
R R
N
N N
Problem
A butane-pentane splitter is to operate at 8.3 bar with
the following feed composition:
For a specification of not more
than 1 mol of the light key in the
bottom product and not more
than 1mol of the heavy key in
the top product, and a reflux
ratio of 2.5, make a stage-by-
stage calculation to determine
the product composition and
number of stages required.
To estimate the dew and bubble
points, assume that nothing
heavier than the heavy key
appears in the tops, and nothing
lighter than the light key in the
bottoms.