Chapter # 05 Equipment design

5.6 DESIGN OF DISTILLATION COLUMN

In industry it is common practice to separate a liquid mixture by distillating the
components, which have lower boiling points when they are in pure condition
from those having higher boiling points. This process is accomplished by partial
vaporization and subsequent condensation.
5.6.1CHOICE BETWEEN PLATE AND PACKED COLUMN:
Vapour liquid mass transfer operation may be carried either in plate column
or packed column. These two types of operations are quite different. selection
scheme considering these factors fewer than four headings.
i! "actors that depend on the system i.e. scale, foaming, fouling factors,
corrosive systems, heat evolution, pressure drop, liquid holdup.
ii! "actors that depend on the fluid flow moment.
iii! "actors that depends upon the physical characteristics of the column and
its internals i.e. maintenance, weight, side stream, size and cost.
iv! "actors that depend upon mode of operation i.e. batch distillation,
continuous distillation, turndown, intermittent distillation.
The relat!e "ert# $% &late $!er &a'(e) '$l*"+ are a# %$ll$,#:
i! #late column are designed to handle wide range of liquid flow rates
without flooding.
ii! If a system contains solid contents, it will be handled in plate column,
because solid will accumulate in the voids, coating the packing
materials and making it ineffective.
Production of gasoline from naphtha $%&
Chapter # 05 Equipment design
iii! 'ispersion difficulties are handled in plate column when flow rate of
liquid are low as compared to gases.
iv! "or large column heights, weight of the packed column is more than
plate column.
v! If periodic cleaning is required, man holes will be provided for cleaning.
In packed columns packing must be removed before cleaning.
vi! "or non(foaming systems the plate column is preferred.
vii! 'esign information for plate column are more readily available and
more reliable than that for packed column.
viii! Inter stage cooling can be provide to remove heat of reaction or solution
in plate column.
ix! )hen temperature change is involved, packing may be damaged.
*.&.+ D#tllat$+ C$l*"+ De#-+ Ste&#
'esignation of design basis
,perating conditions
'etermination of equilibrium stages
-ize of the column
'esign of plate
Production of gasoline from naphtha $%.
Chapter # 05 Equipment design
5.6.. De#-+at$+ $% De#-+ Ba##:
C$"&$+e+t#
Fee) "$l
%ra't$+
T$& "$l %ra't$+
B$tt$" "$l
%ra't$+
/
+
%.0&0. %.10.+
2/
0
%.%$$+ %.%+%*
2
+
/
&
%.%$$% %.%+%%
2
3
/
1
%.%$+. %.%+3+
2
0
/
$%
%.%+0. %.%0*$
2
*
/
$+
%.%+*+ 45 %.%033 %.%%3
2
&
/
$0
%.%01+ /5 %.%%%& %.$%&
2
.
/
$&
%.$+6% %.+1&
2
&
/
&
%.$*60 %.3*3
2
&
/
*
((2/
3
%.$%+% %.++&
2
&
/
$$
((2/
3
%.%%.3 %.%$&
2
*
/
6
((2/
3
%.%%00 %.%$%
5.6./ OPE0ATING CONDITIONS:
,perating #ressure $*.+ atm
Strea"# Te"&erat*re
"eed $+*
o
2
Top -tream 01
o
2
7ottom stream +*%
o
2
8eflux stream 0%
o
2
5.6./ DETE0MINATION OF E1UILIB0IUM STAGES:
Production of gasoline from naphtha $%1
Chapter # 05 Equipment design
9quilibrium data at operating conditions
'etermination of minimum reflux ratio
'etermination of minimum number of stages
'etermination of ideal stages
E2*l3r*" )ata at $&erat+- '$+)t$+:
C$"&$+e+t# K45ALUES
0ELATI5E
5OLATILIT6
/
+
::
2/
0
$&.0%% *$.+*%
2
+
/
&
*.*%% $..$11
2
3
/
1
3.+%% $%.%%%
2
0
/
$%
$.+%% 3..*%
2
*
/
$+
%.*&% $..*%
2
&
/
$0
%.3+% $.%%%
2
.
/
$&
%.$3% %.0%&
2
&
/
&
%.%1% %.+*%
2
&
/
*
((2/
3
%.$1+ %.*&6
2
&
/
$$
((2/
3
%.$%+ %.3+%
2
*
/
6
((2/
3
%.+$1 %.&1%
M+"*" 0e%l*7 0at$:
7y using 2oulburn method,

'

nH
dH
AB
nL
dL
AB
X
X
X
X
R

! $ ;
$
min
<pper pinch Temperature
! ;
3
$
P B p n
T T T T +
! 01 +*% !;
3
$
; 01 +
Production of gasoline from naphtha $%6
Chapter # 05 Equipment design
=$$*.33
o
2
4ower pinch Temperature
! ;
3
$
P B p
T T T T +
! 01 +*% !;
3
+
; 01 +
= $1+.&&.
o
2
4ight 5ey composition in <pper pinch
! $ !; $ ;
fn f
f
nL
X r
r
X
+ +

)here>
r
f
= ratio of composition of light key to heavy key in the liquid part of feed.

I
= relative volatility of components with respect to heavy key.
?
fhi
= composition of heavier than heavy key components in the feed stream.
Now;
"or components heavier than heavy key
C$"&$+e+t# M$l. Fra't$+# 8
%+
2
.
/
$&
%.$+6 %.0%& %.%*+
2
&
/
&
%.$*6 %.+*% %.%0%
2
&
/
*
((2/
3
%.$%+ %.*&6 %.%*1
2
&
/
$$
((2/
3
%.%%. %.3+% %.%%+
2
*
/
6
((2/
3
%.%%0 %.&1% %.%%3
?
fn
= %.$**
Production of gasoline from naphtha $$%
Chapter # 05 Equipment design
fH
fL
f
X
X
r

%01+ . %
%+*+ . %

f
r
= %.*+
! $ !; $ ;
fn f
f
nL
X r
r
X
+ +

! $** . % $ !; *+ . $ ;
*+ . %
+ +

=%.+6&
f
nL
nH
r
X
X
*+ . %
+6& . %

= %.*&6
@ow using this equation,

'

nH
dH
AB
nL
dL
AB
X
X
X
X
R

! $ ;
$
min

'

*&6 . %
%%%& . %
.* . $
+6& . %
%033 . %
! $ .* . $ ;
$
=$.60.
,ptimum 8eflux 8atio ranges from ;$.$ A $.*!B8 min.
I choose the optimum reflux ratio, by plotting the graph bCw total annual cost and
reflux ratio. ;Diven in appendix!
reflux ratio taken is 9.:9

M+"*" N*"3er $% Sta-e#:
7y using "enskeEs 9quation>
Production of gasoline from naphtha $$$
Chapter # 05 Equipment design

LK
b
LK
HK
d
HK
LK
m
X
X
X
X

ln
ln
1
1
]
1

,
_

,
_

.* . $ ln
%%3 . %
$%& . %
%%%& . %
%033 . %
ln
1
]
1

,
_

,
_

b d
=$0 plates with reboiler
N*"3er $% I)eal Sta-e#:
<sing 9rbar ( Faddox graph ;fig $$.$$ 2G8 Vol. &!
N + partial condenser 24
N 23
A't*al N*"3er $% Sta-e# a+) Fee) L$'at$+:
Plate E%%'e+';:
<sing ,E2onnell method ;2oulson Vol.&!
! log; * . 3+ *$
a a
E

)here>
H
a
= average viscosity of liquid, m@sC m
+
Production of gasoline from naphtha $$+
Chapter # 05 Equipment design
I
a
= 8elative volatility of light key
H
a
= %.$.$+ m @sC m
+
-o,
! .* . $ B $.$+ . % log; * . 3+ *$

E
= &1.%+ J
ctual number of stages ;@
actual
!
@
actual
= @
ideal
C 9
o
= +3C%.&1
= 30 ;excluding partial condenser!
"eed location
7y, using kirkbridge 9quation>
1
1
]
1

,
_

,
_

,
_

,
_

+
log +%& . % log
dHK
bLK
fLK
fHK
B
!
"
"
"
"
!
B

1
1
]
1

,
_

,
_

,
_

,
_

+
%%%& . %
%%3 . %
%+* . %
%01 . %
+$$ . $&6
+.$ . $36
log +%& . % log
B
!

$3 . +
B
!

B !
$3 . +
B ! t#ta$
+
( )
B
$ $3 . + 30 +

$$
-o feed is entering at $$th plate from bottom.
Production of gasoline from naphtha $$3
Chapter # 05 Equipment design
5.6.5 T0A6 DESIGN
M$lar Fl$, 0ate $% Strea"#:
"eed, " 3%1.01 kg molChr
Top #roduct, ' $&6.+$ kg molChr
7ottom product, ) $36.+. kg molChr
8eflux, 4n 060.$% kg molChr
5a&$*r Fl$, 0ate:
in rectifying section, Vn &&3.3% kg molChr
in stripping section, Vm *$3.$$ kg molChr
L2*) Fl$, 0ate#:
in rectifying section, 4n 060.$% kg molChr
in stripping section, 4m &*+.31 kg molChr
4mC) 0.&1
Ph;#'al C$+)t$+#:
Top Bottom
Vapour 'ensity, kgCm
3
1..1 30.3&
Production of gasoline from naphtha $$0
Chapter # 05 Equipment design
4iquid density, kgCm
3
*%0.& .6&.3
Vapour flow rate, m
3
Csec %.601& %.$1.*
4iquid flow rate, m
3
Csec %.%$++ %.%$%+
Vapour G 4iquid velocities can be found by using following formulae respt.
Vapour flow rate =
3&%%

%
&#$'t a(g %m

4iquid flow rate =

3&%%

%
&#$'t a(g Lm

Da"eter $% C$l*"+:
( )
( )
+ C $
+
%0. . % +. . % $.$ . %
1
]
1

+
%
% L
t t (
$ $ u

)here>
<v = maximum allowable vapour velocity, based on the gross ;total!
2olumn cross(sectional area, mCs,
l
t
= plate spacing, m, ;range %.* (($.*!
Plate S&a'+- < =.5 "
@ow, by putting values in above formula we get vapour velocity as under,
T$& B$tt$"
Production of gasoline from naphtha $$*
Chapter # 05 Equipment design
Vapour velocity, mCs %.30 %.+$3
@ow,
'iameter of column can be calculated as,
% %
)
C
u
%
!

)here>
'
%
is the maximum vapour rate, kgCsec
7y putting values we get as,
2olumn 'iameter, '
c
$.%* m
)e based our design on bottom diameter.
-o, I take diameter = 3.* ft
$.%&. m
Tra; De#-+:
Tower application or service #roduct finishing
Tower inside 'iameter $.%&. m
Tray type 2ross flow
Tray spacing %.*%1 m
@o. of down comers C tray $
Ca&# Data:
Production of gasoline from naphtha $$&
Chapter # 05 Equipment design
0 in standard cap size is selected for 3.* ft column, so that
all data about cap becomes fixed.

2ap ,' = 0 in =%.$%$& m
2ap I' =%.%610 m
#itch &%
%
K;triangular!
-pacing %.%3$.* m
@o. of rowsCtray 1
Inside /eight above tray %.$%%% m
@o. of slotsCcap, @s ;selected from table! *$
/eight of slot, /s, %.%31$ m
)idth of slot, ws %.%%3$.* m
skirt /eight, s %.%%&3* m
-hroud ring height, hsr %.%%&3* m
8iser ,'. %.%&61* m
I'. %.%&&&. m
8iser height above tray floor %.%1+**m
D$,+ Fl$, Area> A
)%
?
It ranges from $% A +% J of tower area.
Thus for $*J of tower area %.$30 m
+
L2*) D#tr3*t$+ Area> A
la
?
It ranges 1 A +% J of tower area.
Production of gasoline from naphtha $$.
Chapter # 05 Equipment design
nd for $& J of tower area %.$03 m
+
E+) Wa#ta-e> A
e,
?
It ranges from . A ++ J of tower area
nd for $* J of tower area %.$30m
+

N$. $% 'a&# @tra;?
( )
*
e' $a df C
C
a
A A A A

+ +

( )
%%1$ . %
$30 . % $03 . % $30 . % 160 . % + +

= &% caps
reasL
rea =
0
+
!
Total cap area =

,
_

0
+
!

2ap inside cross(sectional area, a

c
%.%%.&%& m
+

Total cap inside cross(sectional areaCtray,

c
%.0*& m
+

8iser inside cross(sectional areaCcap, a

r
%.%%306 m
+

Total riser inside cross(sectional areaCtray,

r
, %.+%6 m
+

8iser outside cross(sectional areaCcap, a

ro
, %.%%313+ m
+

Total riser outside cross(sectional areaCtray,

ro
,%.++6 m
+

nnular area per cap. ( )

+ +
0
r# *i a
d d a

%.%%3..3 m
+
Production of gasoline from naphtha $$1
Chapter # 05 Equipment design

Total annular areaCtray,

a
%.++& m
+

8eversal area C cap,arE, %.%%366 m

+

Total reversal areaCtray %.+360 m

+

-lot areaC cap,a

s
, ;@sB/sB)s! %.%%&$. m
+

Total slot area C tray ,

s
, %.3. m
+
Tra; Detal#:
4ength of outlet weir I
w
,
<sually taken from &% A 1% J of diameter
of column
I take .*J of diameter of column %.1%%+* m
/eight of weir above tray floor, h
w
;+.* A 3.* in.! %.%.&+ m
/eight of top of cap slots ;depends on /s!
above tray floor %.%*%1 m
-tatic slot submergence or seal, h
ss
, %.%31$ m
/eight of bottom of 'own comer
above tray floor %.%&61* m
8iser slot seal %.%*%1 m
Production of gasoline from naphtha $$6
Chapter # 05 Equipment design
Per%$r"a+'e $% Tra;:
Top Bottom
0e#)e+'e t"e + )$,+'$"er?
down comer area,
d
;<sing graph bCw
)eir length and down comer area!%.$30 m
+
%.$30 m
+
effective height of down comer ,h
de

h
de
= -t Mh
w
C$+ %.*10+ m %.*10+ m
time= ;
d
Bh
de
! C V
l
&.* sec 1.% sec
Sl$t#:
( )( )
3
+
3
$
3+

,
_

,
_

+ + C ( $
(
s
'
%
h

)here>
h
s
= slot opening, or pressure drop through slot, in, $iquid,
V = total vapour flow through tray, ft
-
.se*
@c = number of caps per tray
@s = number of slots per cap
)s = width of slot ;rectangular!, in,
slot opening, h
s
%.%0+ m %.%+3& m
Faximum slot velocity;$+.$CN
g
!
$C+
0.61 mCsec +.* mCsec
Finimum slot velocity ;3.0CN
g
!
$C+
$.0$1 mCsec %..$ mCsec
-uper facial slot velocity, u
o
= VC
s
+.*& mCsec %.%*+ mCsec
Production of gasoline from naphtha $+%
Chapter # 05 Equipment design
Pre##*re Dr$&:
Caps:
Top Bottom
0#er Pre##*re Dr$&> h
r
?
( )
%6 . +
+
$
$$$ . %
1
]
1

,
_

r
%
L
r
r
A
% d
h

)here>
d
r
= dia of riser +.&+* in +.&+* in
N
4
= density of liquid 3$.03 lbC ft
3
06.& lbC ft
3
N
v
= density of vapour %.*0. lbC ft
3
+.$0 lbC ft
3
V = volumetric flow rate 33.* ft
3
Csec &.&++ ft
3
Csec

r
= total riser area +.+* ft
+
+.+* ft
+
7y solving equation,
h
r
= #ressure drop ;in in of liquid! %.%.6 in %.%*1 in
0e!er#al a+) A++*l*# Pre##*re Dr$&> h
ra
?

( )
.$ . $
+
$
+
+ &1 . %
1
]
1

,
_

,
_

r
%
* "
r
L
ra
A
%
a a
a
h

)here>
a
r
= inside riser area = in
+
*.0$ *.0$
a
x
= 8eversal area = in
+
&.$1* &.$1*
Production of gasoline from naphtha $+$
Chapter # 05 Equipment design
a
c
= inside area of cap = in
+
$$..6 $$..6
7y solving equation,
h
ra
= #ressure drop ;in Oin/ of liquid! %.%1& %.%&+
0e'ta+-*lar Sl$t Dr; &re##*re Dr$&>
P
s
h
?
( )
.3 . $
+
$
P $&3 . %
1
]
1

,
_

+
% C
L
+
A
%
d h

)hereL
d
c
= diameter of cap = in 3.1.0 3.1.0

s
= total area of slot = ft
+
3.613 3.613
7y solving equation,
h
s
Q = #ressure drop ;in Oin/ of liquid! %.%3&1 %.%+&

T$tal )r; &re##*re )r$&?
P P
+ ra r C
h h h h + +
;Inches of liquid! %.$6$1 %.$0&
Wet 'a& &re##*re )r$&, ;in of liquid! =
+
$

'

,
_

a
+
L
%
+
a
a
A
%

)here>
a
s
= area of slot Ccap = in
0
6.*& 6.*&
a
a
= annular areaC cap = in
0
*.1* *.1*

+
$

'

,
_

a
+
L
%
+
a
a
A
%

%.3& %.3$
"rom graph ;fig 1($$* 4udwig, vol. +, p $&.!
The values of 2
w
areR.
2
w
%.$1 %.$0
Production of gasoline from naphtha $++
Chapter # 05 Equipment design
h
c
= h
c
QC2
w
$.%&* $.%0+
h
cmax
= h
r
Mh
ra
M;/
s
Ms! $.6$* $.1.
Since h
c
is less than h
c,max
., cap is O.K. and not blowing under the shroud
ring.
He-ht $% L2*) $!er Wer; Top Bottom
"irst calculate,
4
g
C ;l
w
!
+.*
$..3+ $0.01
nd
l
w
C' %..* %..*
)here>
4
g
= flow rate of liquid in gallonsCmin
l
w
=length of weir = ft
<sing graph ;fig 1($%0 4udwig, vol. +, p $*6!
"actor,"
w
$.%6 $.%.*

,
_

)
g
) 1)
$
L
2 h %6+ . %
;3n! $..&+ $.*0
L2*) -ra)e+t A@9:
Fean tray width = ;d
c
M l
w
!C+
= ;3.*M+.&+*!C+ 3.%&+* ft =%.630 m
A##*"e) L2*) De&th> h
1
h
$
= h
w
M h
ow
M ;SC+!
assume
0.1&+ in 0.&* in
4
g
Cmean tray width ;gallonCmin. ft! &3.$0 *+.79
Production of gasoline from naphtha $+3
Chapter # 05 Equipment design
U+'$rre'te) AB@+$. $% 0$,# (inches !.!" !.!"
V
%
;N
v
!
$C+
$.0%$ $.%%&&
"rom graph 2
v
;fig 1($$3 4udwig, vol.+!$.%& %.6.
)here>
S = liquid gradient in inches of liquid
V
o
= -uperficial velocity based on column area ;ftCsec!
3.01+ %.&11
2
v
= correction factor for uncorrected liquid gradient
@o. of rows = 1
C$rre'te) A@9 C+'he# $% l2*)D =.119 =.=E=5
T$tal Pre##*re Dr$&@Tra; :; in inches of liquid!
h
t
<h
'
Fh
##
Fh
$,
FA@9
)here>
h
c
;inches of liquid! $.%&* $.%0+
h
ss
;inches of liquid! $.* $.*
h
ow
;inches of liquid! $..&+ $.*0
SC+ ;inches of liquid! %.$$+ %.%1%*
h
t
< h
'
F h
##
F h
$,
F A@9 /./.: /.1695

T$tal Pre##*re Dr$&@Tra; ;in inches of water!
Production of gasoline from naphtha $+0
Chapter # 05 Equipment design
3.%%. +.1*
8ange for pressure drop is +( 0 in of water Ctray
-o pressure drop is with in the range
#ressure drop for trays ;in in, of water!
"or +3 plate above, and $$ plate below &6.$&$ 3$.3*
;mm of /g! 19:.99 5E.5G9
D$,+'$"er Pre##*re Dr$&:
'own comer friction loss plus underflow loss, h
du
+
006
*& . %

,
_

d
g
du
A
L
h %.%366 in %.%+06 in
in mm of /g %.%.0** %.%0&*+
)here>

d
= down comer area in ft
+
L2*) he-ht + )$,+ '$"er:
/
d
= h
w
M h
ow
M h
d
M h
t
M S %.+%.. m %.$6*. m
/
d
T U -t which is in range.
Free He-ht + D$,+'$"er:
" = -
t
M h
w
( /
d
%.316 m %.0% m
Production of gasoline from naphtha $+*
Chapter # 05 Equipment design
Thr$, $!er ,er:
t
w
= %.1 V h
ow
B "W
$C+
$%1.6 mm 66.6 mm
D;+a"' Sl$t Seal:
h
ds
= h
ss
M h
ow
M SC+ 1*.&6 mm .6.+& mm
L2*) E+tra+"e+t:

( )
d *
f
A A
e (#$f$#'rat
%
+

$.*$ mCsec %.+66 mCsec

)hereL
V
f
= -uperficial velocity based on active area mCsec

2alculateL
+
$
.* . $%
3 . +.

,
_

+
% L
%
2
t
%
+

3.*+ +.%0.
"rom graph, ;fig 1($$& 4udwig, vol. +, p $&6!
)
e
C ;h
ow
M h
ss
Mh
s
X ! %.* %.%+*
nd
W
e
in Kg/min m
2
0.024 0.002!
Production of gasoline from naphtha $+&
Chapter # 05 Equipment design
9ntrainment in 5gCmin ;)
e
B;
c
A +
d
!!%.36 %.$*.
9ntrainment ratio %.%%.1 %.%%3%&
The value of entrainment is low, so spacing is quite good.
He-ht $% C$l*"+:
/eight of column ; +% inches tray spacing!
/
c
= ;@
actual
A $! -t M /
= ;30 A $! %.*%1 M $.6$1
= $1..* m
SPECIFICATION SHEET OF DISTILLATION
COLUMN D49G=
I)e+t%'at$+:
Item 'istillation column
Item @o. T($%+
@o. required $
Tray type 7ubble cap tray
F*+'t$+: -eparation of 4ight /.2 from /eavy /.2
O&erat$+: 2ontinuous
Production of gasoline from naphtha $+.
Chapter # 05 Equipment design
Materal ha+)le)
"eed Top 7ottom
Yuantity 3%1..01 5gmolChr $&6.+$$ kgmolChr $36.+. 5gmolChr
2ompositions
4ight key
/eavy key
+.*+ J
0.1+ J
0.3 J
%.%& J
%.3% J
$%.& J
Temperature $+*
o
2 01
o
2 +*%
o
2
De#-+ Data
#ressure = $*.+ atm 8eflux ratio = +.6+L$
@o.of trays = 30 2ap size = %.$%$&m
'iameter of column= $.%&. m @o. of 2apsCtray = &%
-hell thickness = $$.11.mm )eir length = %.1%%+* m
2orrosion allowance=+.%mm )eir height =.&.+ mm
Tray spacing = %.*%1 m 'own comer area =%.$30 m
+
/eight of column = $1..* m ,verall efficiency = &1J
Top 7ottom
#ressure dropCtray = 3.%%. +.1* in. of water
9ntrainment ratio = %.%%.1 %.%%3%&
Production of gasoline from naphtha $+1