Distillation Column Design
Distillation Column Design
Distillation Column Design
Author:
Ageel Buhlaigah 200872740
Group (5)
Submitted to:
Abstract:
In this report, the design of distillation columns was carried out. The number
of stages (trays), the stage on which the feed enters, reflux ratio, diameter of both
stripping and rectify sections, the operating velocity, overall efficiency of the
column ,the length of the tower and the material of construction are calculated and
tabulated in table 1and 2.
INTRODUCTION
Theoretical Background:
A.1.Distillation Column Design:
For the minimum number of trays:
( )
( )
(1)
( ) ( )
(2)
( )
(3)
( ) { ( )* + } (4)
For the overall efficiency of the column, the following equation is used:
(5)
Where:
To find the diameter of the column, the following equation will be used:
[ ] (6)
Where Uop is the operating vapor velocity in ft/s, and can be found by the
following formula:
(7)
The fraction is typically lays in between 0.65 to 0.9, and good performance at 75
% of flooding velocity.
The flooding vapor velocity based on net area of vapor flow is determined from
the following relation:
( ) √ (8)
is the surface tension of liquid in dynes/cm, and is tha capacity factor and a
function of flow parameter FP
For 18-in tray spacing (as recommended from heuristics for tower trays):
(9)
Where is the flow parameter and the following relation is used to find it:
(10)
WL and WV are the mass flow rate of liquid and vapor and densities are mass
densities.
(11)
Sieve tray designs probably provide the majority of installed tray types used in the
process industry and are widely accepted due to their excellent operating
characteristics, low cost Investment and low maintenance requirements. As a
result, sieve tray was chosen for constructing the internal stages.
Figure: A photo for a sieve tray.
(12)
( ) (13)
Where is the fraction of the column cross-sectional area that is available for
vapor flow above the tray. Typically lies between 0.85 - 0.95 and 0.9 will be
used.
(14)
Or
(15)
(16)
Where V is Ib moles/hr
(17)
Or
(18)
Combining equations (13), and (14), we can solve for angle and length of the
weir
The head of clear liquid in the downcomer, , can be determined from the sum
of heads that must be overcome.
(19)
On sieve trays, the liquid gradient , across the tray is often very small and is
usually ignored.
The head of liquid required to overcome the pressure drop of gas on a dry tray,
, can be measured experimentally or estimated (Ludwig, 1995) from
( ) (20)
The orifice coefficient, , can be determined (in inches )from the correlation of
Hughmark and O’Connell (1957). This correlation can be fit by the following
equation (Kessler and Wankat, 1987):
( ) (21)
Where is the tray thickness. The minimum value of ⁄ is 1.0. The weir
height, , is the actual height of the weir. The minimum weir height is 0.5 inch
with 2 to 4 inches more common.
The height of the liquid crest over the weir, , can be calculated from the
Francis weir equation.
⁄
( ⁄ ) (22)
Where is in inches. In this equation is the liquid flow rate in gal/min that
is due to both L and e. the factor is a modification factor.
There is a frictional loss due to flow in the downcomer and under the downcomer
onto the tray. This term, , can be estimated from the empirical equation
(Ludwig, 1997; Bolles, 1963).
( ) (23)
Where is in inches and is the flow area under the downcomer apron in
ft2. The downcomer apron typically has a 1-in gap above the tray.
(24)
The condition for avoiding excessive weeping can be determined from estimation
of (Kessler and Wankat, 1987) as
(25)
(26)
Results:
Table 1: Summary for distillation column T-202
Distillation Summary Table for T-202
F Z Top Xd Bot Xb
ac 1.4588 0.0004 1.28592 0.0285 0 0
eth 169.9502 0.0466 28.23158 0.6257 141.9188 0.0394
ea 3.2823 0.0009 3.384 0.075 0.10806 0.00003
h2o 3466.474 0.9505 12.21398 0.2707 3454.318 0.959
bu 3.2823 0.0009 0 0 3.2418 0.0009
aa 2.1882 0.0006 0 0 2.1612 0.0006
3646.635 45.11549 3601.748
F Z Top Xd Bot Xb
eth 141.9188 0.0394 137.3882 0.6897 4.53056 0.0013
ea 0.10806 0.00003 0 0 0.10806 0
h2o 3454.318 0.959 61.752 0.31 3392.566 0.997
bu 3.2418 0.0009 0.05976 0.0003 3.18204 0.0009
aa 2.1612 0.0006 0 0 2.1612 0.0007
199.2 3402.548
= 1.45
( )
( )
Therefore,
N = 2.5 (25+1)
For Nfmin
Nf = ( )
For the overall efficiency of the column, the following equation is used:
For
6 = 83.8%
( )
= 0.273
Surface tension:
( ) √
* +
From heuristics:
For towers about 0.9 m dia, add 1.2 m at the top for vapor disengagement,
and 1.8 m at bottom for liquid level and reboiler return.
Material of construction (MOC):
Since the liquid and gas mixtures are not corrosive and the column temperature
under 400 C. The carbon steel is the appropriate MOC.
Figure: 3 Entrainment correlation from Fair (1963)
Downcomer area:
( )
Vapor Velocity:
Chosen tray is a std. 14 gauge tray with thickness (T tray) = 0.078 in with a common
hole diameter do= 3/16 inch for normal operation and clean service. Pitch Std.
spacing between the holes of 3.8do = 0.1725 inches. A 2.5 in space between the
edge holes and the column wall is chosen, and a space of 4 in between the edge
hole and the tray weir.
Orifice coefficient:
( ) ( )
( )
( )
Assume
From figure (10-20) in CHE 306 (Separation Process Engineering, Wankat 2nd ed)
Fw=1
( )
⁄
( )
From the equality above, weeping would not be a problem in the rectifying section.
= 1.957
( )
( )
N = 2.5 (12+1)
For Nfmin
Nf = ( )
For the overall efficiency of the column, the following equation is used:
For
1 = 73%
( )
= 0.2958
Surface tension:
( ) √
* +
From heuristics:
For towers about 0.9 m dia, add 1.2 m at the top for vapor disengagement,
and 1.8 m at bottom for liquid level and reboiler return.
Since the liquid and gas mixtures are not corrosive and the column temperature
under 400 C. The carbon steel is the appropriate MOC.
Figure: 3 Entrainment correlation from Fair (1963)
Downcomer area:
Active area:
( )
Area of the hole:
Vapor Velocity:
Chosen tray is a std. 14 gauge tray with thickness (T tray) = 0.078 in with a common
hole diameter do= 3/16 inch for normal operation and clean service. Pitch Std.
spacing between the holes of 3.8do = 0.1725 inches. A 2.5 in space between the
edge holes and the column wall is chosen, and a space of 4 in between the edge
hole and the tray weir.
Orifice coefficient:
( ) ( )
( )
( )
Assume
From figure (10-20) in CHE 306 (Separation Process Engineering, Wankat 2nd ed)
Fw=1
( )
⁄
( )
From the equality above, weeping would not be a problem in the rectifying section.
Process control:
Conclusion:
To sum up, the design of distillation columns (T-202 and T-204) was carried
out. Details of staged column design such as stage geometry, determination of
column efficiency, calculation of column diameter, downcomer sizing, and tray
layout were discussed and estimated. The dimensions of T-202 were found to be
D=2.48 m,L= 58.63 m and n= 78 trays. Also, dimensions of the column T-204
were found to be D=3.14 m,L= 35.2 m and n= 46 trays. Moreover, the sieve tray
specifications, weir length, vapor flooding velocity, and liquid weeping were
calculated. The flooding velocity of the vapor was ensured to be in the acceptable
range. Also, the weeping would not be a problem as shown.
Reference(s):