INDG1030

Chemical Plant Design

I Term 2019

Separation Units

Santiago D. Salas, Ph.D. Lecture 8.2

Distillation towers

2
Introduction
Distillation is the process of separating the components or
substances from a liquid mixture by using selective boiling
and condensation.

3
Introduction

Distillation may result in a complete separation, or a

partial separation that increases the concentration of
selected components in the mixture. In either case, the
process exploits differences in the relative volatility of
the mixture's components.

In chemical engineering, distillation is a unit operation

of high importance that purifies or separates the
components within a process stream.

4
Principal components of a distillation unit
2

1. Distillation column: 3
vessel + trays.
2. Heat exchangers: 1
condenser + reboiler. 4

3. Reflux drum (vessel).

4. Reflux pump(s).

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Typical variables

(𝑳𝟎 )
(𝑫)

(𝑭)

(𝑽) (𝑳)

(𝑾)
6
Typical input data
System: binary, acetone – methanol
𝒛𝑭 = 𝟎. 𝟒 → fraction of the lighter component in the feed
stream.
𝒚𝑫 = 𝟎. 𝟗 → fraction of the lighter component in the
distillate or over head products stream.
𝒙𝒘 = 𝟎. 𝟏 → fraction of the lighter component in the
bottoms stream.
𝑻𝒇 = 𝟖𝟎 ℃
𝑷𝒇 = 𝟏 𝒂𝒕𝒎 (assuming constant pressure).
We assume constant relative volatility of acetone, equal to 1.2,
and need to calculate the thermal load of the reboiler and
condenser.
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Mass and enthalpy balances
Determine the thermal
loads in the condenser
and reboiler.

8
Mass and enthalpy balances
Let, external reflux ratio

Thermal charge of the condenser

Total mass balance:

Total enthalpy balance:

9
Mass and enthalpy balances

Thermal charge of the reboiler

Total mass balance (column):

Total enthalpy balance (column):

10
Methods
The important parameters that define the degree of
separation (purity) of a mixture in a distillation column
are:
1. External reflux ratio: R = Lo/D
2. Internal reflux ratio, L/V
3. Number of theoretical stages or transfer units.

Simple methods to calculate separation parameters in

binary systems:
1. Method of McCabe-Thiele
2. Method of Ponchon-Savarit

11
McCabe-Thiele method

General assumptions:
Small heat losses or solution heats.

Common simplifying assumptions:

- The liquid molar flow is constant in each of the
areas of the column.
- The L / V ratio is constant all the zones.

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Rectifying Section

13
Rectifying Section

14
Rectifying Section

Global mass balance:

Lighter component mass balance:

Reflux ratio:

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Rectifying Section
From the first two equations above we get:

And, considering the reflux ratio:

Evaluating, n = 0 and calculating the intercept for a reflux

ratio known, we get two points that allow us to build the
line of operation for the enrichment zone. The slope of
the line of operation is L/V (internal reflux ratio).

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Graphic representation : Rectifying Section

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Stripping Section

18
Stripping Section

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Stripping Section

Global mass balance:

Lighter component mass balance:

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Rectifying Section
From Eq. (6) and (7) we get:

Evaluating at 𝑵 + 𝟏 (reboiler) we have that 𝒙𝒘 is in

equilibrium with 𝒚𝑵+𝟏 and in the equilibrium graph we
can reach 𝒙𝑵 , and reach a point on the operation line of
the stripping zone.

Now, we can build the operation line of the stripping

zone.

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Graphic representation : Stripping Section

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Feed Section

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Feed Section

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Feed Section
Global mass balance:
(9)

Enthalpy balance:

Considering that the enthalpies of the saturated vapors,

and the saturated liquids are similar.
At the feed tray, we get:
(10)

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Feed Section
Combining (9) and (10):

(11)

Knowing q, we can find L’ (equation 11), and with this

data calculate V’ (equation 6). Finally, we calculate
the intercept or slope of the operation line for the
stripping area.

q → moles of liquid flow in the stripping section that

results from the introduction of each mole of feed.

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Feed Section
Determine the equation of the feed:

Cold feed (below bubble point) q>1

Feed at bubble point (saturated liquid) q=1
Feed partially vapor 0<q<1
Feed at dew point (saturated vapor) q=0
Feed superheated vapor q<0
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The feed line (q-line)

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Equilibrium curve at minimum reflux

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Equilibrium curve at theoretical reflux ratio

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31
Tray Efficiency

μL * αLK,HK
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Heuristics
1. Distillation is usually the most economical
method for separating liquids, superior to
extraction, absorption, crystallization, or others.
2. For ideal mixtures, relative volatility is the ratio
∗
𝑃𝑣,1
of vapor pressures: 𝛼1,2 = ∗
𝑃𝑣,2

3. Tower operating pressure is most often

determined by the temperature of the
condensing media, 38 - 50 °C (100 - 120 °F) if
cooling water is used, or by the maximum
allowable reboiler temperature to avoid
chemical decomposition/degradation.

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Heuristics
4. Sequencing of columns for separating
multicomponent mixtures:
a) Perform the easiest separation first, that is, the one
least demanding of trays and reflux, and leave the most
difficult to the last.
b) When neither relative volatility nor feed composition
varies widely, remove components one by one as
overhead products.
c) When the adjacent ordered components in the feed
vary widely in relative volatility, sequence the splits in
order of decreasing volatility.
d) When the concentrations in the feed vary widely but
the relative volatilities do not, remove the components
in order of decreasing concentration.
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Heuristics
5. Economical optimum reflux ratio is in the range of
1.2 to 1.5 times the minimum reflux ratio, 𝑅𝑚𝑖𝑛 .
6. The economically optimum number of theoretical
trays is near twice the minimum value 𝑁𝑚𝑖𝑛 .
7. The minimum number of trays is found with the
Fenske-Underwood equation:
𝑥 𝑥
𝑙𝑛 1 − 𝑥 / 1−𝑥
𝑜𝑣ℎ𝑑 𝑏𝑡𝑚𝑠
𝑁𝑚𝑖𝑛 =
𝑙𝑛 𝛼
𝛼 = 𝛼𝑜𝑣ℎ𝑑 ∙ 𝛼𝑏𝑡𝑚𝑠
where, 𝑥 is the mole fraction of more volatile component in the
over head / bottoms product.
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Heuristics
7. Minimum reflux for binary or pseudo-binary mixtures
is given by the following when separation is essentially
complete (𝑥𝐷 ≈ 1) and 𝐷/𝐹 is the ratio of overhead
product to feed rate:
𝐷 1
𝑅𝑚𝑖𝑛 = , when feed is at the bubble point.
𝐹 𝛼−1
𝐷 1
𝑅𝑚𝑖𝑛 + 1 = , when feed is at the dew point.
𝐹 𝛼−1

8. A safety factor of 10% of the number of trays

calculated by the best means is advisable.
9. Reflux pumps are made at least 10% oversize.

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Heuristics
11. The optimum value of the Kremser absorption
𝐿
factor, A = , is in the range of 1.25 to 2.0.
𝑚𝑉
12. Reflux drums usually are horizontal, with a liquid
holdup of 5 min half-full. A takeoff pot for a
second liquid phase, such as water in
hydrocarbon systems, is sized for a linear velocity
of that phase of 1.3 m/s (0.5 ft/sec), minimum
diameter is 0.4 m (16 in).
13. For towers about 0.9 m (3 ft) diameter, add 1.2 m
(4 ft) at the top for vapor disengagement, and 1.8
m (6 ft) at bottom for liquid level and reboiler
return.
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Heuristics
14. Limit the tower height to about 53 m (175 ft)
maximum because of wind load and foundation
considerations. An additional criterion is that L/D
be less than 30 (20 < L/D < 30 often will require
special design).

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Distillation Sequence

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Example: NGL recovery

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Operating problems

41
Column Costs
• Column
– Pressure of the vessel
– Trays
– Packing
– Material of Construction
• Reboiler and Condenser (area)
• Pumping Costs: feed, reflux, reboiler.
• Other vessels
– Surge tank before column, reboiler accumulator,
condensate accumulator.

42
Cost estimation equipment
0 2
log10 𝐶𝑝′ = 𝐾1 + 𝐾2 log10 𝑨 + 𝐾3 log10 𝑨
𝑲𝟏 𝑲𝟐 𝑲𝟑
Vessels Volume, [𝒎𝟑 ]
Horizontal 3.5565 0.3776 0.0905 [0.1 - 628]
Vertical 3.4974 0.4485 0.1074 [0.3 - 520]
Towers Volume, [𝒎𝟑 ]
Tray & packed 3.4974 0.4485 0.1074 [0.3 - 520]
Trays Area, [𝒎𝟐 ]
Sieve 2.9949 0.4465 0.3961 [0.07 – 12.30]
Valve 3.3322 0.4838 0.3434 [0.7 – 10.50]
Demister 3.2353 0.4838 0.3434 [0.7 – 10.50]

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Cost estimation equipment
0 2
log10 𝐶𝑝′ = 𝐾1 + 𝐾2 log10 𝑨 + 𝐾3 log10 𝑨
𝑲𝟏 𝑲𝟐 𝑲𝟑
Vessels Capacity, [𝒎𝟑 ]
Horizontal 3.5565 0.3776 0.0905 [0.1 - 628]
Vertical 3.4974 0.4485 0.1074 [0.3 - 520]
Heat exchanger Capacity, [𝒎𝟐 ]
Shell & tube 4.3247 −0.3030 0.1634 [10−1000]
Kettle reboiler 4.4646 -0.5277 0.3955 [10−100]
Pumps Capacity, [𝒌𝑾]
Centrifugal 3.3892 0.0536 0.1538 [1−300]
Pos. displ. 3.4771 0.1350 0.1438 [1-100]

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𝑭𝒑 for process vessels
The pressure factor for horizontal and vertical process
(pressurized) vessels of diameter D [meters] and operating
at a pressure of P [barg] is based on the ASME code for
pressure vessel design.

𝑃+1 𝐷
+ 0.00315
2[850 − 0.6(𝑃 + 1)]
𝐹𝑝,𝑣𝑒𝑠𝑠𝑒𝑙 =
0.0063
If 𝑭𝒑,𝒗𝒆𝒔𝒔𝒆𝒍 is less than 1 (corresponding to 𝑡𝑣𝑒𝑠𝑠𝑒𝑙 < 0.0063
m), then 𝐹𝑝,𝑣𝑒𝑠𝑠𝑒𝑙 = 1. For pressures less than 0.5 barg,
𝐹𝑝,𝑣𝑒𝑠𝑠𝑒𝑙 = 1.25.

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𝑭𝒑 for heat exchangers & pumps

log10 𝐹𝑝 = 𝐶1 + 𝐶2 log10 𝑷 + 𝐶3 log10 𝑷 2

The units of pressure, P, are bar gauge or barg (1 bar = 0.0 barg)
unless stated otherwise.
For heat exchangers bayonet, fixed tube sheet, floating head,
kettle reboiler and U-tube:

𝐶1 = 0.03881, 𝐶2 = −0.11272 and 𝐶3 = 0.08183; Pressure

range: 5 < 𝑃 < 140

For centrifugal pumps:

𝐶1 = −0.3935, 𝐶2 = 0.3957 and 𝐶3 = −0.00226; Pressure

range: 10 < 𝑃 < 100
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𝑭𝒑 for Trays

𝟐
10 0.471+0.08516 log 10 𝒏𝑻 −0,3473 log 10 𝒏𝑻 , 𝒏𝑻< 20
𝐹𝑝,𝑡𝑟𝑎𝑦 = ቊ
1 , 𝒏𝑻 ≥ 20

𝒏𝑻, number of trays

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Cost Estimation

𝐶𝐵𝑀 = 𝐶𝑝0 𝐹𝐵𝑀 = 𝐶𝑝′

0 𝐵 +𝐵 𝐹 𝐹
1 2 𝑀 𝑃

Process vessels 𝑩𝟏 𝑩𝟐
Horizontal 1.49 1.52
Vertical (including towers) 2.25 1.82

Heat exchangers 𝑩𝟏 𝑩𝟐
Shell & tube 1.63 1.66

Pumps 𝑩𝟏 𝑩𝟐
Positive displacement 1.89 1.35
Centrifugal 1.89 1.35

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Correction for inflation

𝐶𝐸𝑃𝐶𝐼 holds for CHEMICAL ENGINEERING PLANT COST

INDEX.

𝐶𝐸𝑃𝐶𝐼2017
𝐶𝐵𝑀, 2017 = 𝐶𝐵𝑀
𝐶𝐸𝑃𝐶𝐼𝑏𝑎𝑠𝑒(2001)

𝐶𝐸𝑃𝐶𝐼2017
𝐶𝐵𝑀, 2017 = 𝐶𝐵𝑀
397

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Take Home Ideas!

✓ Distillation towers should be considered as the first option

when selecting a separation system.

✓ Distillation systems consist of a distillation tower, a reboiler,

condenser, reflux drum and pumps.

✓ A distillation tower has a rectifying section, a stripping

section and a feed section.

Lecture 8.2