11.

6 Distillation and Absorption Efficiencies for tray and packed towers

11.6.1 Tray Efficiency
In all the previous discussions of theoretical trays or stages in distillation, we assumed that
the vapor leaving a tray was in equilibrium with the liquid leaving.

However, if the time of contact and the degree of mixing on the tray are insufficient, the
streams will not be in equilibrium. As a result the efficiency of the stage or tray will not be
100%. This means that we must use more actual trays for a given separation than the
theoretical number of trays determined by calculation.

Three types of tray or plate efficiency are used:

1. Overall tray efficiency E
0
,

2. Murphree tray efficiency E
M

3. Point or local tray efficiency E
MP
(sometimes called Murphree point efficiency).

11.6.2 Types of Tray Efficiencies

1. Overall tray efficiency:
The overall tray or plate efficiency E0 concerns the entire tower and is simple to use,
but it is the least fundamental. It is defined as the ratio of the number of theoretical or
ideal trays needed in an entire tower to the number of actual trays used:

2. Murphree tray efficiency.
The Murphree tray efficiency EM is defined as follows:

3. Point Efficiency.
`
1
*
`
1
`
+
+

=
n n
n n
MP
y y
y y
E
Where
y`
n
=concentration of vapor at specific point in plate n
y`
n+1
= concentration of vapor entering the plate n at the same point
y* = concentration of vapor that would be in equilibrium with x
n
`

4. Relationship between tray Efficiencies
) / log(
)] 1 / ( 1 log[
L mV
L mV E
E
M
o
+
=
5. Estimation of Efficiencies of Tray and Packed Towers
5.1. Efficiency of Tray Towers.
For estimating the overall tray efficiency of bubble-tray towers for distillation, the OConnell
(01) correlation can be used (K2) with about a 10% error.
The following equation for these data from Lockett (Li) can be used for sieve and valve
trays as well, but predictions will be slightly conservative:
245 . 0
) ( 492 . 0

= o
L o
E
Where E0 is fraction efficiency, a is relative volatility of the two key components
at the average tower temperature, and L is the molar average viscosity in cp of the
liquid feed at the aver-age tower temperature of the top and the bottom. Most
typical efficiencies are between 40 and 80%.
To estimate the overall tray efficiency for absorption towers, the OConnell
correlation(01) can be used. This correlation is represented by the equation (S3)
5.2. Efficiency of random-packed towers.
For estimates for random packing, Equation. can be used to determine the
HETP for second- and third-generation packings only (S2):
HETP = 0.0180d
P
(SI)

HETP = 1.5d
P
(English)
where HETP is in m and d is packing diameter in mm. In English units, HETP is
in ft and d is in in. Also, for small-diameter towers, where the tower diameter D is
less than 0.60 m (2 ft), HETP = D, but not less than 0.3 m (1 ft).

For vacuum service (S3),
HETP = 0.0180d
P
+ 0.15 (SI)

HETP = 1.5d
P
+ 0.50 (English)
5.3. Efficiency of Structured Packing in towers
HETP = 100/a+0.1 (S.I)
HETP = 100/a+0.33 (English)
Please See Example 11.5.1 P729
11.7.1 Introduction
In the case before, the main assumptions in the method we made are that the
latent heats are equal, sensible heat differences are negligible, and constant
molal overflow occurs in each section of the distillation tower.
But now in fractional distillation using enthalpy-concentration data, the molal
overflow rates are not necessarily constant.
The analysis will be made using enthalpy as well as material balances.
11.7 Fractional distillation using enthalpy-concentration method
An efficient separation can be achieved if the a > 1.05
Efficiency of separation process highly depends on the reflux ratio and
stages

Reflux
Manipulated variables
11.7.2 Enthalpy-concentration Data
An enthalpy-concentration diagram for a binary vapor-liquid mixture of A and B
takes into account latent heats, heats of solution or mixing, and sensible heats
of the components of the mixture.
The saturated liquid line in enthalpy h kJ/kg or kJ/kg mol is calculated by

h =x
A
c
pA
(T-T
0
) +(1-x
A
)c
pB
(T-T
0
) +AH
sol

where,
x
A
= weight or mole fraction A.
T, T
0
= boiling point of the mixture and ref. temp.in K .
c
pA
, c
pB
= liquid heat capacity of comp. A and B.

AH
sol
= heat of solution at T
0
in kJ/kg mol.

The saturated vapor enthalpy line of H kJ/kg or kJ/kg mol of a vapor composition y
A

is calculated by,

H =y
A
[
A
+c
pyA
(T-T
0
)] +(1-y
A
)[
B
+c
pyB
(T-T
0
)]
where,

A
= c
pA
(T
bA
-T
0
) +
Ab
- c
pyA
(T
bA
-T
0
)

B
= c
pB
(T
bB
-T
0
) +
Bb
- c
pyB
(T
bB
-T
0
)

Ab
,
Bb
= the latent heat of comp. A and B at normal the
boiling point T
bA
. ,T
bB
respectively.
c
pyA
, c
pyB
= vapor heat capacity of comp. A and B .

T
0
is equal to the boiling point of the lower boiling comp. A. This means
A
=
Ab
.
Hence, only
Bb
must be corrected to
B
.
Example 11.6-1: Enthalpy-Conc. Plot for Benzene-Toluene.
Prepare an enthalpy-concentration plot for benzene-toluene at 1 atm pressure.
Equilibrium data are given in Table 11.01-1 and Figs. 11.1-1 and 11.1-2.
Physical property data are given in Table 11.6-1.
c
p
(kJ/kg mol.K)
Component T
b
(C) Liquid Vapor
Bb
(kJ/kg mol)
Benzene (A) 80.1 138.2 96.3 30820
Toluene (B) 110.6 167.5 138.2 33330
Table 11.6-1. Physical Property Data for Benzene and Toluene.
Solution
A reference temperature of T
0
= 80.1 C will be used for convenience so
that the liquid enthalpy of pure benzene (x
A
= 1.0) at the boiling point will be
zero.
(1) For the first point we will select pure toluene (x
A
= 0). For pure toluene
at the boiling point of 110.6 C, with zero heat of solution and data from
Table 11.6-1,
h = x
A
c
pA
(T-T
0
) + (1-x
A
)c
pB
(T-T
0
) + AH
sol

h = x
A
c
pA
(T-80.1) + (1-x
A
)c
pB
(T-80.1) + 0
h = 0 + (1-0) 167.5

(110.6 80.1) = 5109 kJ /kg mol.

(2) For the saturated vapor enthalpy line, we first must calculate
B
at the
reference temperature T
0
= 80.1 C .
B = cpB (TbB -T0) + Bb - cpyB (TbB -T0)
= 167.5(110.680.1) + 33330138.2(110.6-80.1)
= 34 224 kJ /kg mol.

(3)To calculate H, at y
A
= 0.
H = y
A
[
A
+ c
pyA
(T-T
0
)] + (1-y
A
)[
B
+ c
pyB
(T-T
0
)]
= 0 + (1.0-0) [34224 + 138.2 (110.6-80.1)]
= 38 439 kJ/kg mol.

(4) For pure benzene, x
A
= 1.0 and y
A
= 1.0, since T = T
0
= 80.1, using ,
h = x
A
c
pA
(T-80.1) + (1-x
A
)c
pB
(T-80.1) + 0
h =0
(4)For the saturated vapor enthalpy, at T = 80.1.
H = 1.0[30820 + 96.3(80.1-80.1)] + 0 = 30 820

(5) Selecting x
A
= 0.50, the boiling point T
b
= 92 C and the temperature of
saturated vapor for y
A
= 0.50 is 98.8 C from Fig. 11.1-1. Using equation for the
saturated liquid enthalpy at the boiling point.
h = 0.5(138.2)(92-80.1)+(1-0.5)167.5(92-80.1)=1820
Also,
for y
A
= 0.50, the saturated vapor enthalpy at 98.8 C is
H = 0.5[30820 + 96.3(98.8-80.1)] + (1-0.5)[34224 +138.2(98.8-80.1)]
= 34 716

(6) Selecting x
A
= 0.30 and y
A
= 0.30, h = 2920 and H = 36268. These values are
tabulated in Table 11.6-2 and plotted in Fig. 11.6-1.
DISTILLATION
Saturated Liquid Saturated Vapor
x
A
Enthalpy, h y
A
Enthalpy, H
0 5109 0 38439
0.30 2920 0.30 36268
0.50 1820 0.50 34716
0.80 562 0.80 32380
1.00 0 1.00 30820

Table 11.6-2: Enthalpy-Concentration Data for Benzene-Toluene
Mixtures at 101.325 kPa total pressure.
DISTILLATION
Enthalpy
of mixture,
H or h
(kJ /kg mol
mixture)
0
0.2 0.4
0.6 0.8
1.0
Mole fraction benzene, x
A
or y
A
.
0
10000
20000
30000
40000
H vs y
A
(saturated vapor)
h vs x
A
(saturated liquid)
tie line
Fig. 11.6-1: Enthalpy-concentration plot for example 11.6-1
The enriching-section operating line, mass balance





Arrangements;





However, the V
n+1
and L
n
may vary, equation will not
become a straight line
1 1
1
+ +
+
+ =
n
D
n
n
n
n
V
Dx
x
V
L
y
1 n n
V L D
+
= +
1 1 n n n n D
V y L x Dx
+ +
= +
Distillation in Enriching Section of Tower.
Making an enthalpy balance (eliminating the assumption of
constant molal overflow in McCabe-Thiele method)


Enthalpy balance for condenser


Eliminating the terms q
c
D n n n n
Lh H V h D V H V + =
+ + + 1 1 1 1 1
) (
d D c
Dh Lh H V q =
1 1
c D n n n n
q Dh h L H V + + =
+ + 1 1
D n n n n
Dh H V h L H V + =
+ + 1 1 1 1

In order to plot the operating line, the terms V
n+1
and L
n
must be determined
first.

If the reflux ratio is set, V
1
and L

are known.

The values H
1
and h
D
can be determined from an enthalpy-concentration plot.

If the value of x
n
is selected, it is a trial-and-error solution to obtain H
n+1
since
y
n+1
is not known.

Distillation in Stripping Section of Tower.

The stripping-section operating line




Making an enthalpy balance,





Using the similar steps to that for enriching section to solve for
stripping section. Assume equimolal overflow.

1 1
1
+ +
+
=
m
W
m
m
m
m
V
Wx
x
V
L
y
D D C
F c W D R
W R m m m m
Dh Lh H V q
Fh q Wh Dh q
Wh q h W V H V
=
+ + =
+ + =
+ + +
1 1
1 1 1
) (
A liquid mixture of benzene-toluene is being distilled using the same
conditions as in example 11.4-1 except that a reflux ratio of 1.5 times the
minimum reflux ratio is to be used.
The value of R
m
=1.17 from example 11.4-2 will be used.
Use enthalpy balances to calculate the flow rates of the liquid and vapor at
various points in the tower and plotted the curved operating lines.

Determine the number of theoretical stages needed.
Example 11.6-2: Distillation Using Enthalpy-Concentration Method.

Solution
The given data are as follows;
F = 100 kg mol/h,
x
F
= 0.45 ,
x
D
= 0.95,
x
W
= 0.10,
R = 1.5(1.17) = 1.755,
D = 41.2 kg mol/h,
W = 58.8 kg mol/h.

the feed enters at 54.4 C and q = 1.195. The flows at the top of
the tower are calculated as follows.
L/D = 1.755; L = 1.755(41.2) = 72.3;
V
1
= L+D = 72.3 + 41.2 = 113.5.
The saturation temp. at the top of the tower for y
1
= x
D
= 0.95 is
82.3 C from Fig. 11.1-1. Using equation,

H
1
= 0.95[30820+96.3(82.3+80.1)]+(1-0.95)[34224+138.2(82.3-80.1)]
= 31 206.
The boiling point of the distilled D is obtained from Fig.11.1-1 and is 81.1 C.
The enthalpy h
D
then,
h
D
= 0.95(138.2)(81.1-80.1)+(1-0.95)(167.5)(81.1-80.1)= 139

Following the procedure outlined for the enriching section:

step 1,
a value of x
n
= 0.55 is selected. Assuming a straight operating line, an
approximate value of y
n+1
is obtained.,
695 . 0 345 . 0 ) 55 . 0 ( 637 . 0
) 95 . 0 (
5 . 113
2 . 41
5 . 113
3 . 72
1
= + =
+ =
+ n n
x y
step 2,
using Fig. 11.6-1, for x
n
=0.55, get h
n
=1590
and for y
n+1
=0.695, get H
n+1
=33240.
Substituting into equation and solving,



Then, calculate L
n

109.5 = L
n
+ 41.2, L
n
= 68.3

step 3,
substituting into enriching operating line
5 . 109
) 139 ( 3 . 72 ) 31206 ( 5 . 113 1590 ) 2 . 41 ( ) 33240 (
1
1 1
=
+ =
+
+ +
n
n n
V
V V
70 . 0 ) 95 . 0 (
5 . 109
2 . 41
) 55 . 0 (
5 . 109
3 . 68
1
= + =
+ n
y
This calculated value of y
n+1
= 0.7 is sufficiently close to the approximate value
of 0.695 so that no further trials are needed.

Selecting another value for x
n
=0.70 and solving for




Then,
L
n
= 110.8-41.2 = 69.6

Substituting into,

793 . 0 ) 95 . 0 (
8 . 110
2 . 41
) 7 . 0 (
8 . 110
6 . 69
1
= + =
+ n
y
791 . 0 ) 95 . 0 (
8 . 110
2 . 41
) 7 . 0 (
8 . 110
3 . 72
1
= + =
+ n
y
In Fig. 11.6-3, the points for the curved operating line in the enriching section
are plotted. This line is approximately straight and is very slightly above that
for constant molal overflow.

The condenser duty is calculated.
q
C
= 113.5(31206)-72.3(139)-41.2(139) = 3 526 100 kJ /h

To obtain the reboiler duty q
R
,
values for h
W
and h
F
are needed. Using Fig. 11.6-1 for x
W
= 0.10, h
W
= 4350.
The feed is at 54.5 C. Using equation to calculate h
F
,

h
F
= 0.45(138.2)(54.5-80.1)+(1-0.45)(167.5)(54.5-80.1)
= -3929
Then,
q
R
= 41.2(139)-58.8(4350)+3526100-100(-3929)= 4180500
Making a material balance below the bottom tray and around the reboiler,
L
N
= W + V
W


Rewriting equation for this bottom section,
V
W
H
W
= (V
W
+W)h
N
+ q
R
Wh
W


From the equilibrium diagram, for x
W
= 0.10, y
W
= 0.207, which is the vapor
composition leaving the reboiler. For equimolal overflow in stripping section,
L
m
= L
n
+ Qf =72.3+1.195(100)=191.8
V
m+1
= V
n+1
(1-1.195)100 = 133.0

Selecting y
m+1
= y
W
= 0.207, and value of x
m
= x
N
is obtained.
1 1
1
+ +
+
=
m
W
m
m
m
m
V
Wx
x
V
L
y
) 10 . 0 (
133
8 . 58
0 . 133
8 . 191
207 . 0 =
N
x
Solving,
x
N
= 0.174. From Fig. 11.6-1 for xN = 0.174,
h
N
= 3800, and
for y
W
= 0.207, H
W
= 37000. Substituting into

V
W
H
W
= (V
W
+W)h
N
+ q
R
Wh
W
V
W
(37000)=(VW + 58.8)(3800)+4180500-58.8(4350)

Solving , V
W
= 125.0. Then calculated L
N
= 183.8. Substituting into
equation to solve for x
N
,


This value of 0.407 is sufficiently close to the approximate value of 0.412 so that
no further trials are needed.

The two points calculated for the stripping section are plotted in Fig. 11.6-3. This
stripping line are also approximately straight and is very slightly above the
operating line for constant molal overflow.

Using the operating line for the enthalpy balance method, the number of
theoretical steps is 10.4. For the equimolal method 9.9 steps are obtained.

0
0
0.2 0.4 0.6 0.8
1.0
0.2
0.4
0.6
0.8
1.0
Mole fraction in liquid, x
Mole fraction
in vapor, y
x
F

Fig. 11.6-3: Plot of curved operating line for example 11.6-2
q-line
Example
A feed containing 40 mole percent n-hexane and 60 percent n-octane is fed to a
distillation column. A reflux ratio of 1.2 is maintained. The overhead product is 95
percent hexane and the bottoms 10 percent hexane. Find the number of
theoretical stages and the optimum feed stage. Assume that a total condenser is
used. The column is to operate at 1 atm.

The equilibrium data are as follow:

x 0 0.1 0.3 0.5 0.55 o.7 1.0
y 0 0.36 0.70 0.85 0.90 0.95 1.0
EXAMPLE
MOLE FRACTION OF
HEXANE
ENTHALPHY
SAT. LIQUID SAT. VAPOR
0 7000 15700
0.1 6300 15400
0.3 5000 14700
0.5 4100 13900
0.7 3400 12900
0.9 3100 11600
1.0 3000 10000
Obtain enthalpy-composition diagram
Fix the feed point F, and product points D and B using stream compositions
and enthalpies
Use the overhead product enthalpy and the reflux ratio to find the adjusted
enthalpy of the overhead. Plot it as point D', on a vertical line with point D.
Construct the overall enthalpy line from point D' through the feed point. It
intersects a vertical line drawn through point B at point B'.
Plot point V1. For a total condenser, the composition entering the
condenser is the same as the overhead product, so this point will be
vertically above point D on the saturated vapor curve.
Follow the tie line from point V1 to the saturated liquid curve. This
intersection will be point L1.
Construct an operating line connecting points D' and L1. The intersection of
the operating line with the saturated vapor curve will be point V2.
Repeat the two preceding steps until one of the V or L points is to the left of
the overall enthalpy line. Once it is crossed, construct operating lines using
points Li and B'.
When xi is less than xB, construction is finished

DISTILLATION
1) Plot the enthalpy concentration data.








2) Plot the point for feed and product
DISTILLATION
DISTILLATION
DISTILLATION
DISTILLATION