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Introduction to Distillation:
Steady State Design
and Operation
1. Introduction
2. Steady-state design
3. Steady-state operation
BASF Aktiengesellschaft
1. Introduction to distillation
King (Wiley, 1980) on distillation design
Shinskey (McGraw-Hill, 1984) on distillation control
Kister (McGraw-Hill, 1990) on distillation operation
B
I usually number the stages
from the bottom (with reboiler=1),
but many do It from the top
Alternative: Packed column
Vapor-liquid equilibrium (VLE) = Equilibrium line
y=K(x)
Non-ideal
Difficult separation
Easy sep.
(almost az.)
Ideal mixture
Stage i+1
Material balance stage i (out=in):
Li+1 Li xi + Vi yi = Li+1xi+1 + Vy-1yi-1
Vi Xi+1
yi
Li
Vi-1 xi
yi-1
Stage i-1
The equlibrium stage concept is used for both tray and packed columns
• N = no. of equilibrium stages in column
Typical: 0.7
• Tray column: N = No.trays * Tray-efficiency
• Packed columns: N = Height [m] / HETP [m] Typical: 0.5 m
TOP
Simplified energy balance:
Vi = Vi+1 (“constant molar flows”)
VLE: yi = Ki(xi)
Material balance stage i (out=in):
Li xi + Vi yi = Li+1xi+1 + Vi-1yi-1
or (around bottom):
BTM Li+1xi+1 –Vi yi = B xB
Constant molar flows:
xi+1 = (V/L) yi + (B/L) xB
”Operating line”:
•Straight line giving xi+1 as a function of yi
•Bottom: Goes through point (xB,xB)
Stage i+1
Total reflux: Li+1
Vi = Li+1 Vi xi+1
yi = xi+1 O
yi
Stage i
Li
Vi-1 xi
yi-1
Examples design
• =1.5. xL,top = 0.99, xH,btm=0.99
– Separation S = (0.99/0.01)2 = 9801
– Nmin = lnS/ln = 9.19/0.405 = 22.7
– Vmin/F = (0.99-0.01)/(1.5-1) + 0.5 = 2.46
– Column A: N=40 (a bit small) gives V=1.3 Vmin
Important insights:
Vmin is a good measure of energy usage Q
Vmin is almost independent of purity
Vmin is weakly dependent on feed comp. (feed liquid: get vaporization term D/F≈ zF)
Design: To improve purity (separation): Increase N
N and Vmin both increase sharply as → 1
Example. Decrease from 2 to 1.1:
Nmin increases by a factor 7.3 ( =ln 2/ln1.1)
Vmin increases by a factor 10 ( =(2-1)/(1.1-1))
NON-OPTIMAL
OPTIMAL:
•No pinch
•or: pinch on both
sides of feed stage
(mixture on feed stage has
same composition as feed)
Given: For vapor feed and sharp sep. of binary mixture: Vmin/F = 1/(-1)
IDEAL VLE (constant α)
MIXTURE
0.9
(binary, 41 stages,
99% purities, =1.5) Typical:0.8
Flat profile at column ends
0.7
0.6
xi = 0.5
mole fraction 0.4
of light
0.3 Here: No pinch (flat profile) around feed
component
0.2
because we have “few” stages
compared to required separation
0.1
0
0 5 10 15 20 25 30 35 40 45
BTM TOP
stage no.
Binary distillation: Typical column profiles
We may maintain the right split D/F by keeping a column temperature constant.
BTM TOP
Binary distillation: T Flat around feed when pinch
Typical temperature profiles
LT ¼ -X
Again profile is much more linear
in terms of logarithmic temperatures:
342K
Stage no. !
355K
Shortcut analysis
heavy non-key
heavy key
(heptane)
(hexane)
BTM
x
Vapor phase composition
99.9% recovery
TOP
Stage
BTM
y
Flow profile
99.9% recovery
TOP
V
L
Stage
BTM
Flows
Temperature profile
99.9% recovery
TOP
Stage
BTM
Temperature [K]
Turn profile around
Temp.
TOP BTM
Stage
Log (xL/xH)-plot (“key ratio profile”):
Use to check feed location
TOP
Stage
BTM
With feed moved from stage 10 to 15
TOP
Stage
10
log(xL/xH) has pinch above feed:
15 Too many stages above feed
BTM
Relative volatility
(Feed back to stage 10)
Stage
BTM
McCabe-Thiele diagram
99.9% recovery
TOP
y’C5
BTM x’C5
3. Steady-state operation
Smaller effect
Implication for control
Important to get the right split (D/F)
avoid breakthrough of light components in bottom
avoid breakthrough of heavy components in top
LIGHT
TC
F
HEAVY
B
Idea: The column is a “tank” filled with heavy and light component
Need to adjust the split (D) to keep constant holdups of light and heavy
Simplest: “Profile feedback” using sensitive temperature
Temperature profile multicomponent
360
Feed:
350 25% C4
25% C5 (L)
340
L/F=0.6: 25% C6 (H)
330 99.9% recovery 25% C7
Temp. of L and H
320
L/F=0.3: 20 stages
310 99% recovery D/F = 0.5
of L and H Vary L/F
300
You may consider moving the feed location (look at profile), but usually
has limited effect
Normally the only “fix” is to get more stages in your column
Trays:
+ More easy to clean
+ Better for large capacity columns
+ Larger holdup (typically, 2 times larger): Advantage for control (“have more time”)
- Can have inverse response in bottom of column (- effect - difficult to predict)