COLUMN INTERNALS Part 1 - TRAYS
COLUMN INTERNALS Part 1 - TRAYS
COLUMN INTERNALS Part 1 - TRAYS
Part 1 : TRAYS
Program at the By
Indian Institute of Petroleum
IIP Dehradun K . Jayanth Pai
4 October , 2006 . Chemical Engineering Group
A-303 , L&T Powai
1 October 2006 1
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Brief Introduction Of Speaker
K . Jayanth Pai
Educational Qualifications
Lunch -“-
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Panoramic View of a Refinery
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Distillation - A Widely Used Process
L 0
V 1
1
V 2 L 1
V 3 L 2
TOP PRODUCT
3
FEED
V 4 L 3
4
V 5 L 4
5
L 5
V
BOTTOM
6
Separation into various
PRODUCT products is based on the B
difference in relative
Separation of a given Feed Volatility of the constituents
into two or more products of the feed mixture .
Column Internals provide
the site for this separation
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Other Mass Transfer Processes
Absorption
Components of gas dissolve in contacting liquid (HCl absorption in Water)
Stripping
Components of liquid stripped into contacting gas (NH3 stripping from Sour Water)
Extraction
Separation involving the contact of two insoluble liquid phases (LPG Sulphur
Compounds extraction in Caustic solution)
• Trays
• Random Packing
• Structured Packing
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Fractional Distillation Of Crude Oil
Crude Oil is distilled into various fractions with Light Vapors , Gasoline as topmost
product and Asphalt , Bitumen as the bottommost .
Separation is carried out using differences in volatility of various hydrocarbons
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Fractional Distillation Of Crude Oil – contd.
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Fractional Distillation Of Crude Oil
- contd.
C1 to C4 Gases LPG
The Crude Column has Trays
as the principal mass
C5 to C9 Naphtha transfer separations’ device
Chemicals
C5 to C10
Gasoline Petrol
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Basic Tray Operation
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General Layout Of A Tray And Definitions – contd.
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Tray Types
Sieve Trays
1. Essentially a perforated tray with downcomer .
Easy to manufacture , inexpensive and widely
used in petroleum and chemical industries .
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Tray Types – contd.
– Inexpensive to build
– Easy to install
– Can design for wide range of flow rates
– Use sloped segmental designs if liquid-
vapor disengagement difficult
Cross-Flow Pattern
Multiple-Pass Trays
-
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Single And Multi-Pass Trays
Center Downcomer
Off-Center
Downcomer
Experience suggest that efficiency increases with Length of Flow Path for comparable
hydraulic parameters such as weir load and vapor velocity through bubbling area .
Number of Passes should be increased primarily to increase capacity for a given
diameter under downcomer limiting Conditions . Extreme care is needed to balance flow
between panels of trays with three or more passes . Unequal L/V among panels is
detrimental to both Efficiency and Capacity . In addition a minimum flow path length
of 16 “ (400 mm) is required for manways .
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Downcomers , Weirs , and other Attachments
Imagine the weir as a dam with water flowing over it . The crest
height over the edge of the dam is a function of the specific liquid load
Liquid Feeds – Make sure the design does not produce a non-uniform flow
pattern on the tray . In particular look for ways of absorbing the momentum of
the incoming liquid and of distributing it over the tray .
Flashing Intermediate Feeds – Care must be taken that the downcomer action
is not spoiled by the flashing feed overloading the downcomer with vapor or by
causing boiling in the downcomer through heat transfer from a hotter feed .
Access – All technical solutions which are acceptable from a process design point
of view must also be assessed in terms of mechanical design and ease of access .
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Downcomers , Weirs , and other Attachments
Inlets
• Design to avoid excessive
weeping and entrainment Feed In Front View
18 inch Min or
• should be Minimum 12 inch a Tray Spacing
above liquid surge level and
18 inch or one Tray Spacing
below the bottommost tray
12 inch
Minimum
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Downcomers , Weirs , and other Attachments
Transition Arrangements
As the number of passes changes from one
section to another a suitable pass
transition arrangement is used to smoothly
move both liquid and vapor from one
section to another . Liquid handling is
more involved requiring correct sizing of
notches and down-pipes . Transition
arrangements also arise when one section
is packed and the other trayed . A
judicious choice of collectors , down-pipes
, and redistributors is used . Mistakes in Tray Transition Arrangement
designing transition regions have led to
costly reworks and delays in commissioning
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Downcomers , Weirs , and other Attachments
Reboiler Returns
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Downcomers , Weirs , and other Attachments
Anti-Jump Baffles
Splash Baffles
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Downcomers , Weirs , and other Attachments
Inlet sumps are prone to foul and also create potential flow Inlet Sump
restrictions between the sump bottom and outlet weir below. (Inlet Seal Pan)
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Downcomers , Weirs , and other Attachments
Tray Blanking
Trays are blanked to reduce the
minimum operating point as required
by various situations . Trays that
must operate at rates well below
those for which they were designed Inlet and outlet blanking Blanking the sides
might need blanking . Trays which must have additional inherent capacity for some
future expansion might require blanking prior to expansion . Trays with diameters
established by considerations other than loads to be handled might require blanking
In such an arrangement suitable hardware must be provided to ensure that all liquid
passes over the active area only .This method is likely to be more expensive than
any of the others and should be used only if the benefits are expected to justify
the additional cost .Flow Path Length is a key variable and the method selected
should not reduce it below 30 inches . It is simpler and more economic to install
blanking strips parallel to the long dimension of the tray panels . Inlet and outlet
blanking should be considered when the area to be blanked is relatively small and the
flow path length is long .
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Performance Diagram For Trays
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Spray Entrainment (Jet Flooding) and Blow Flooding
Blow Flooding is another form of entrainment flood . There is little liquid on the
tray floor which may appear to be dry . With such a low liquid level there is no
downcomer seal so that the vapor travels up the downcomer . If the vapor velocity
in the downcomer based on the downcomer area exceeds the system limit liquid will
not ravel down the column and stable operation cannot be achieved . As with jet
flooding column performance deteriorates before blow flooding occurs .
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Downcomer Choke Flooding
disengagement .
flood .
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Maximum Efficient Capacity and System Limit Or Ultimate Capacity
Maximum Efficient Capacity is not a flooding criterion but sometimes used for
systems which are limited by jet flood or entrainment . As a tray approaches its
jet flood point it starts to entrain liquid to the tray above which constitutes
back-mixing of liquid and reduces tray efficiency . This often means that a tray
common practice to design to a given percentage of the flooding load on the basis
It is often possible to increase the capacity of a column above the flooding point
of its trays by changing the tray design but there is a limit to such increases .
The System Limit is a combination of vapor and liquid loads which is a function
will occur .
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Tray Pressure Drop
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Tray Pressure Drop
Pressure drop by gas flow through perforations : f(n) gas flow rate, fraction free
area and valve coefficient of perforations (or valves) being used.
Pressure drop caused by liquid present on tray : f(n) outlet weir height, inversely
with gas flowrate and directly with liquid flowrate.
Pressure drop of gas flow through tray without liquid : Dry Tray Pressure Drop.
Hole load factor is gas hole velocity times square root of gas to liquid density.
The pressure drop of a valve tray differs from the sieve tray pressure drop mainly,
because the gas flowing through the valves in the tray floor experiences a different
flow resistance.
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Flow Regimes On Trays
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Bubble and Spray Regimes
Bubble Regime
Spray Regime
When vapor load is much higher than liquid load vapor becomes the continuous phase
with a large range of bubble sizes contained in it , appearing as a highly turbulent
droplet cloud . Most droplets are found at high elevations from the tray floor .
This is relatively commonly found in industrial columns where the vapor rates are
much higher than the liquid rates , notably vacuum columns .
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Froth and Emulsion Regimes
Froth Regime
A chain of bubbles moves around the mobile froth covered
by droplets . With a rise in vapor rate vapor jets form at
the perforations and there is mixed bubbling and jetting TRAY
action . OPERATION
At higher vapor rate froth slowly converts to a spray
regime .
Due to the wide operating range over which it occurs froth
regime is the commonest regime and of industrial
importance.
Emulsion Regime
Spray Regime is seen in columns operating in vacuum . If the liquid loads are also
high one sees a Froth regime under these conditions . In distillations over 15 bar
the Emulsion regime is likely to occur .
Most low and medium pressure columns operate in Froth Regime as it covers a
wide L/V range . Depending on a rise in either vapor or liquid rate the Froth
regime gets converted to a Spray or Emulsion regime , respectively .
Strictly speaking the Francis Weir formula is applicable only to the Emulsion
regime and neither the Spray nor Froth regime .
F – Factor is defined as the vapor velocity times the square root of the
vapor density
It is the square root of the vapor kinetic energy and it is important to know
on what area it is based whether column superficial area , bubbling area ,
hole area etc.
F x = u x (ρ v )0 . 5
C – Factor or Capacity Factor originally derived by Souders and Brown in
connection with entrainment from trays comes from taking the ratio of the
drag force to gravity force on a suspended drop of liquid .
0 .5
= ux ρv
(ρ l − ρ v )
Cx
Found to be an extremely useful correlating term . As with
F – Factor it is essential to specify area basis for velocity
The Concepts useful to gain an intuitive feel for tray
capacity are droplet size and terminal velocity . Larger
the droplet size , higher its terminal velocity and the
more difficult it is for a vapor stream to entrain it to
the tray above . 47
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Performance Parameters – contd.
QL / LW
QL / Adc
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Performance Parameters – contd.
Downcomer Widths :
Downcomer width is determined by froth velocity guidelines . With a limiting inlet
velocity it helps to slope the downcomer . For high pressure services care is needed
to see that the slope is not so high that large exit velocities entrain or carry under
small bubbles to the tray below . Side downcomers with outlet weir lengths much
smaller than column diameter cause high holdup and pressure drop . There is limited
experience with downcomers les than 5 % of the column area (Lw/D < 0.6) . Center
and off – center downcomers in multi-pass trays may suffer an efficiency decrease
due to throw of opposing liquid streams if the downcomer width is too small . Anti-
150 mm for side and 200 to 300 mm for center and off – centre downcomers .
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System Derating Factors
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Summary Of Design Guidelines
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Summary Of Design Guidelines - continued
Hole Diameter : Standard hole diameter of 1/2 inch (12.5 mm) is most
commonly used . A larger hole has higher pressure drop and entrainment whereas a
smaller hole is likely to plug or foul .
Hole Spacing : The commonly used patterns are triangular or rectangular . Hole
spacings upto 3 inches are used .
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Summary Of Design Guidelines - continued
Weir Height : Pressure drop increases with weir height , weeping and
entrainment only slightly . Effect of weir height on mass transfer for most
distillation systems is minor . However for stripping , absorption , and some
reacting systems , that are liquid phase controlled , the effect can be significant
. Weir heights 2 - 3 “ (50 - 75 mm) are mostly used for pressure systems , while
1 - 2 “ (25 - 50 mm) for vacuum systems . Higher weirs used in liquid phase
controlled and reacting systems .
Earlier models used equilibrium theoretical trays and tray efficiency (Fenske Overall
Eo , Murphree vapour Emv). Computing models (Aspen Ratefrac™) use non-equilibrium
stages , rate-based general approach . Flow rates, mass transfer coefficients,
interfacial area , liquid hold up are combined into a variable NTU (Number of
Transfer Units). It is computationally intensive, requiring much more input data but
Typical efficiencies from plant tests and experimental programs that vary between
30 - 90 % , depending on test system , tray type , geometry tested, hydrodynamic
conditions , etc.. For new columns , experience , data interpolation (previous
tests/experience and/or published literature), direct scale up from efficiencies
measured in pilot plant column , existing commercial column , empirical prediction
methods (O'Connell) ,theoretical methods (AIChE Manual , Chan & Fair correlation).
When practical test data are available they are usually preferred .
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Tray Efficiency – contd.
1) Which is the best way to correlate vapour phase mass transfer coefficient
2) The mechanisms determining the interfacial area available for mass transfer
3) Use of Francis' weir equation in calculating liquid hold up in the spray regime
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Typical Practical Tray Efficiencies
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About Fractionation Research Inc. (F.R.I.)
Founded in the 1950's to engage in research expensive for any one company.
Responsible for some of the most significant advances in distillation last 50 years .
FRI collects , interprets , analyzes, and presents data at membe rs’ meetings,
The Data models enable practicing engineers of member companies select and
F.R.I.'s facility is the primary independent test forum for new fractionation
As Many
As 14
Japanese Co’s
65 Co’s Only 2
Worldwide Indian Co’s
L&T is one
23 American
Co’s
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FRI Experimental Facilities
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High Capacity Trays - an introduction
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High Capacity Trays – contd.
Objective :
Increase capacity of Internals without changing the Column
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Truncated Downcomer Tray
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Vapor Flow Promoter
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Vapor Crossflow Channelling
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Sieve Tray Design
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Fair’s Correlation for Sieve Tray Jet Flood Prediction
0 .2
σ
Applicability : K = C sb 20
Fractional Hole Area =(Area of holes /
Active Area of tray) >= 10 %
If hole area 8 % then Csb,f = 0.9 Csb,f
If hole area 6 % then Csb,f = 0.8 Csb,f
Hole diameter <= 0.5 “
Weir Height <= 0.15 * (Tray Spacing)
For valve trays approximate using slot area
68
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Column Diameter
π (Dia) 2
Anet (net area) = x
4
x = fraction of column cross-section area available for vapor flow above tray
This is usually 0.85 to 0.95
1 – x = fraction of column area taken up by one downcomer
• Terms in equations vary stagewise , results in different diameters ,
• The largest diameter is used rounded off to the next highest 1/2 ft
increment.
• Diameters < 2 ft are usually constructed as packed columns.
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Column Diameter
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Sieve Tray Layout And Tray Hydraulics
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Sieve Tray Layout and Tray Hydraulics
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Sieve Tray Layout and Tray Hydraulics
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Sieve Tray Layout And Tray Hydraulics
Operating column => downcomer liquid aerated i.e. ρ aerated,liq < ρ clear,liq
Therefore, height of aerated liquid in downcomer > hdc h dc,aerated = hdc / φdc
φ dc = 0.5 is satisfactory φ dc = 0.2 to 0.3 in difficult cases
• To avoid downcomer flooding, tray spacing must be greater than hdc,aerated
ρV v 2o
valve h∆p ,valve = K v
ρ L 2g
vo - velocity of vapor through the holes in the deck, ft/sec
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Tray Hydraulics Software Example
The Tray software is designed to rate trays for distillation, stripping, and absorption applications.
It can be used to rate many types of standard trays commonly found in industry. It rates
multiple fluid loading and multiple types of internals within the same program. The user can thus
compare various operating ranges and tray designs combinations .
The user gets a good approximate tray design and rating for the conditions that are entered.
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Tray Hydraulics Software Example - contd.
Geometry Data Input allows the user to enter the geometric information on the tray(s) to be
rated. This is where all the necessary mechanical information is provided to the program.
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Some Additional Practical Design Aspects
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Some Additional Practical Design Aspects
Numerous case histories are reported where bad design of a liquid drawoff
sump led to a crippling of column performance . Correcting such mistakes
involves costly shutdown and rework which can mean loss of crores of rupees .
Although obvious the importance of proper sizing of drawoff sumps cannot be
overemphasized .
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Some Additional Practical Design Aspects
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Comparison Of Packings And Trays – contd.
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Benefits to Business Units Of Detailed Technical Analyses Of Columns
And Internals
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Shoot your questions !!
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Brief Introduction Of Speaker
K . Jayanth Pai
Educational Qualifications