COLUMN INTERNALS Part 1 - TRAYS

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“DISTILLATION TRAYS , PACKINGS

AND OTHER COLUMN INTERNALS”

Basic Concepts , Simulation , and Column Hydraulic Design

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

B.Tech, Chemical Engg. (1988) I.I.T. Delhi

M.Tech, Process Engg. & Design (1992) I.I.T. Delhi


Work Experience :
After graduation in 1988 , worked in various industries and in varied
functions such as Production , Projects , Research and Development ,
Technical Services , and Design Engineering .
Before joining L&T in June 2004 was with Sulzer Chemtech at Pune in the
Technology Group .
At L&T working as Head of the Chemical Engineering Group in the
Technology and RND Department , and responsible for High-end technical
support to various Business Units on varied aspects of Process Simulation ,
Design , Troubleshooting , and Project & Proposal Engineering
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Programme at IIP Dehradun on “Column Internals"
AGENDA

DATE TIME (Hours) TOPICS Faculty

09.00-10.30 : 1hr 30 min Column Internals Part 1 : TRAYS K . Jayanth Pai

10.30-10.45 Tea Break (15 min)


October 4 , Column Internals Part 2 : PACKINGS
2006 10.45-12.15 : 1hr 30 min -“-
and Other Internals
Wednesday
12.15-12.30 : 15 min Concluding Discussions

Lunch -“-

Programme Faculty : K . Jayanth Pai


Senior Manager and Head – Chemical Engineering Group
PRDH Department
E&C Division , Larsen and Toubro Ltd.
Powai , Mumbai – 400076
Tel : 022-67052991(office) , 022-25700808 / 40059275 (residence) ,
mobile : 0-9819064981
Email : Jayanth_Pai@lntenc.com
Personal email : kjayanthpai@yahoo.com 3
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Contents :

1) Introduction to Distillation Operations


2) Basic Tray Operation , Layout , and Terminology
3) Types of Trays
4) Downcomers , Weirs , and other Attachments
5) Single and Multi-Pass Trays
6) Performance Diagram for Trays
7) Flow Regimes on Trays
8) Performance Parameters
9) Tray Design Guidelines
10) About Fractionation Research Inc.
11) High Capacity Trays
12) Sieve Tray Design Illustration
13) Use of Tray Hydraulics Software
14) Tray Efficiency
15) Some Additional Practical Design Aspects
16) Brief Comparison of Trays and Packings
17) Technical Support to Business Units
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Columns ..Columns .. Everywhere !!

More than half these columns .. ...are Distillation Columns !!

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Panoramic View of a Refinery

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Distillation - A Widely Used Process

“Distillation, King in separations, will remain as the workhorse separation


of the process industries and against which alternate methods must be
judged .” Dr. James R. Fair
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Distillation Column - Basic Function

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)

Efficiency of Mass Transfer processes involving contacting two immiscible


i mmiscible phases
like Gas-
Gas-Liquid or Liquid – Liquid , is dependent on the efficiency of the inter-
inter-
phase contact , in which Area available for intimate contact is the deciding factor
The Column Internals are the means for providing this contacting area .
The three major types of Column Internal are

• 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

CRUDE C10 to C16 Kerosene Jet Fuel ,


COLUMN Heating
Oil

C14 to C20 Diesel Oils Diesel Fuel


Crude
Oil
C20 to C50 Lubricating Oil Lube Oils , Waxes ,
Polishes

C20 to C70 Fuel Oil


Fuel For
Furnace Ships
> C70 Residue Bitumen

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Basic Tray Operation

Active Area : Where mass-transfer occurs .


This is the area on the tray panel where the
two-phase froth forms due to vapor-liquid
contact

Downcomer : Transports liquid tray to tray .


It receives at its top the mixture from the
FREE AREA active area and sends out clarified liquid from its
bottom on to the tray below . The vapor
disengages within the downcomer and is carried
upward to the tray above through the free area

Free Area : For vapor-liquid disengagement


Ability to mix , then separate vapor and liquid ,
limits tray capacity.

Area under entering downcomer and over exiting


Column Is Essentially A
downcomer is inactive .
Cylindrical Vessel
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General Layout Of A Tray And Definitions

Bubbling Area : area enclosed by


the tower walls , outlet weir , and Perforations May Be Lost
inlet
From Tray Ring , Supports ,
edge of tray , and excluding any
Etc.
un-perforated area more than 4 “ wide Downcomer
Downcomer Area
Free Area : minimum area available Seal Area Perforate
for vapor flow or the tower area less d
maximum area at top of downcomer Area ,

Downcomer Edge Bubbling


Area
Tower Area : inside cross sectional (Inlet Weir)
(Seal Pan Edge) Outlet
area of the column
Weir
Flow
Downcomer Top Area : maximum Path
area Length

at the top or entrance of downcomer

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General Layout Of A Tray And Definitions – contd.

Downcomer Bottom Area is the minimum


area at the bottom of the downcomer

Downcomer Seal Area is the area below


the bottom of the downcomer used to seal
the downcomer and distribute the liquid to
the tray

Hole Area is the total perforated area


open to vapor flow

Fractional Hole Area is the ratio of the


hole area to the bubbling area

Zone is a group of trays or number of


equilibrium stages where vapor-liquid
traffic and physical properties are
relatively constant

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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 .

2. General purpose tray with efficiency good


at design conditions .

3. Turndown relatively low although three to one


is quite easily achievable with good design .

4. Non-proprietary and hence serves as an excellent


benchmark for comparison of other options .

5. Good in clean or moderately fouling applications


or when solids are present perforations range from 1/8 inch and
larger, but generally average 1/2 inch
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Tray Types – contd.

Float Valve Trays

1. Better turndown properties

2. More flexible when the feed rate varies

3. Holes fitted with "valves” flat covers can move


up and down

4. Efficiency remains high as gas rate drops


“Float Valve”

5. Standard valve will have higher pressure drop

6. About 15 - 25 % more expensive than sieve trays

7. More likely to foul or plug than a sieve tray

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Tray Types – contd.

Bubble Cap Trays

1. A riser or weir around each hole in tray

2. A cap with slots or holes placed over riser

3. Vapor bubbles through these holes

4. Excellent turndown and flexible satisfactory


operation at very high and very low liquid
flow rates

5. Entrainment greater than of a sieve tray

6. Tray spacing greater than for sieve trays

7. Efficiency same or less than sieve trays Cap

8. Problems with coking, polymer formation, Slots


and fouling mixture
Riser 18
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Tray Types – contd.

Fixed Grid Valve Trays


The fixed grid valve tray consists of valves punched
into a sheet of metal and hence an integral part of
the tray panel

Their Main Advantages are


– Significantly Higher Capacity
– Mechanical Strength and Robustness
– High suitability for fouling service
– Reduced Pressure Drop

Their Main Disadvantages are


– Poor operation at high Turnup / Turndown
ratios
– Slightly Higher cost
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Tray Types – contd.

Fixed Grid Valve Trays – continued

Vapor Emerging From Perforations Vapor Emerging Laterally From


With A Vertical Momentum Keeps Perforations Tends To Break
The Froth Layer Uplifted The Froth Layer

The Smaller Valves More Evenly


Spread Perform Better
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Downcomers , Weirs , and other Attachments

Downcomers And Weirs


They control the liquid distribution and flow

• Circular Pipe commonly used for small


column and pilot plants
• Segmental Downcomer commonly used
for industrial columns
Weir Length

– Inexpensive to build
– Easy to install
– Can design for wide range of flow rates
– Use sloped segmental designs if liquid-
vapor disengagement difficult

Downcomer Top View


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Downcomers , Weirs , and other Attachments

Cross-Flow Pattern

- Works well for average flow rates

– Can be designed to handle solids in the feed Single Pass

Multiple-Pass Trays
-

– Liquid flow divided into 2 sections

– Multiple passes required when gas


Double Pass
liquid flow rates become high.

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Single And Multi-Pass Trays

Vapor Handling Capacity Increases As


Square Of The Diameter And So
Therefore Does Liquid Load

However Weir Length Increases Only


Linearly And Hence Falls Short For A
Simple Single Weir Circular Geometry
Single Two
Pass Pass
Side Downcomer

Center Downcomer

Off-Center
Downcomer

Multiple Passes Simply Increase


The Weir Length So That Specific Three Four
Weir Loads Are Not Excessive Pass Pass
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Single And Multi-Pass Trays - contd.

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

Straight Horizontal Weir Clearance Under Outlet Weir


– Simplest weir design Downcomer

– Cheapest but limited turndown


Adjustable Weir Downcomer Area
– Solves turndown problem Top
– If maladjusted causes excessive Inlet Weir
weeping or trays running dry
– Rarely used these days
Notched Weirs Notches
– Useful for low liquid flow rates

Notches are cut on Outlet Weir reducing Weir


Effective Weir Length is reduced to Baffles , Pickets Baffles , Picket
maintain reasonable specific weir load
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Downcomers , Weirs , and other Attachments

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 .

Intermediate Feeds – Not only is it necessary to absorb liquid momentum and


get a good distribution , it is also necessary to consider ways of achieving good
mixing between the feed liquid and the liquid coming from the tray above .

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

• Baffles needed for


Top View
• Higher velocity feeds
Schoepentoeter
• Feeds containing vapor Type Feed Inlet

Vapor Return At Column


Bottom Flow Pattern

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

Care should be taken to avoid Reboiler

Return impinging on the seal pan as it can

interfere with the down flow of bottom

seal pan liquid , increasing the backup to

unacceptable levels and also cause

vaporization of seal pan liquid

Avoid Reboiler Return through Downcomer

as it eats up the downcomer capacity by

Avoid Reboiler Avoid Reboiler


blocking its cross sectional area . Return Through
Return Impinging
On Seal Pan Downcomer
Premature flooding can then occur .
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Downcomers , Weirs , and other Attachments

Inlets Below Bottom Tray : Single-Pass and


Two-Pass Trays
A common source of problems : care must be taken
to introduce feed properly and avoid damage to
trays above . If feed is from a thermo-syphon
reboiler loop delta P be checked to ensure efficient
operation . Side downcomers are preferred .
Two phase feed is introduced through a special feed
inlet device which dissipates the incoming momentum
and effects a vapor – liquid separation within itself .
Liquid drops to the column bottom and vapor travels
up . For large columns it is necessary to properly
distribute vapor before feeding it to the bed above

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Downcomers , Weirs , and other Attachments

Anti-Jump Baffles

Anti-jump baffles are vertical baffles suspended at the


center line and along the full length of downcomer
entrance to form a partition that deflects the frothy
liquid into the downcomer . They are used above the
center and off-center downcomer entrance areas to help
Isometric View
achieve maximum tray capacity . Vapor expansion near
the outlet weir pumps liquid over the weir . At high
vapor rates the trajectory carries some liquid completely
over most downcomers and onto the opposite active area
. This recycled liquid prematurely floods the tray unless
anti-jump baffles are used . Used only on multi-pass

trays these are high liquid rate applications .


Elevation View
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Downcomers , Weirs , and other Attachments

Splash Baffles

Splash baffles are vertical solid baffles placed as a


shield on he active area side of the overflow weir ,
parallel to the weir , with a clearance from both
deck and weir .
Vertical Splash Baffle
They are used only in very low liquid rate service to
prevent liquid from being blown over the overflow
weir as a spray . They effectively retain low liquid
volumes on the active area of the tray so that the
tray can function in the spray regime without blowing
dry . Hooded splash baffles are used on cartridge
trays which use envelope downcomers . Because these
types of baffles create restrictions to liquid flow
they should be used only for low liquid rates . Hooded Splash Baffle

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Downcomers , Weirs , and other Attachments

Downcomer Seal Pans are the most common method of


sealing the bottom tray .

Drawoff Sumps are commonly used for intermediate


liquid drawoff from a tray column
Downcomer Seal Pan
Inlet Sumps (Inlet Seal Pans) are used for two reasons :
1) To reduce downcomer exit head loss in high liquid rate
cases allowing a positive downcomer seal with low weir
heights , in turn reducing the downcomer backup for greater
capacity . (Often applied in high pressure service .)
2) To provide a positive downcomer seal for all liquid rates ,
Drawoff Sump
particularly low liquid rate service . When the downcomer
clearance is set below the tray floor , a minimum amount of
liquid is required to seal the downcomer .
This improves low liquid rate column start-up and operation .
This is often applied in vacuum service .

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

Four types of blanking patterns are common :


•Inlet and outlet blanking
•Blanking the sides
•Blanking with strips parallel to flow
•Blanking with strips perpendicular to flow
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Tray Blanking – contd.

The ideal way to blank a tray would be


to blank segmental areas on both sides
of the tray such that the active
(perforated) area is , or Blanking with strips Blanking with strips
approaches , a rectangle . parallel to flow perpendicular to flow

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

Flooding is excessive accumulation


of liquids inside the column .
Mechanisms:

1) Spray Entrainment or Jet Flooding


2) Blow Flooding
3) Downcomer Choke Flooding
4) Downcomer Backup Flooding

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Spray Entrainment (Jet Flooding) and Blow Flooding

Jet Flooding is excessive entrainment of liquid droplets to the tray above .


Spray and / or froth occupies the entire space between trays . The downcomer is
operational but its load is increased by recirculating entrained liquid , causing it to
flood . Column performance deteriorates before jet flooding occurs , due to
efficiency loss through liquid entrainment , particularly true of vacuum distillation .
Jet Flooding is common in low liquid load conditions in low pressure columns say
around 5 bar and columns under vacuum operation .

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

Aerated liquid called ‘froth’ enters a

Downcomer and establishes a zone for vapor

disengagement .

Vapor returns to tray space above and clear

liquid flows to the tray below .

When the downward velocity of froth in the

downcomer , usually at the top , is so high

that little or no vapor disengagement occurs ,

the resulting low liquid volume fraction fills

throughout the downcomer causing a backup

flood .

This mechanism is called as ‘choking’ flood .


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Downcomer Backup Flooding

Vapor – liquid disengagement is taking place in the

downcomer but the various components of

downcomer backup exceed the available height in

the downcomer and froth backs up on the tray h∆p


above .
hdc hgrad
Downcomer Backup Flooding occurs when
hdu hcrest
Height Of Dispersion In Downcomer >
hweir
Downcomer Height

The liquid height is defined by condition that

hydrostatic liquid head be sufficient to make the

liquid flow down against the tray pressure drop.

39
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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

cannot be operated satisfactorily close to the flood point . It is therefore a

common practice to design to a given percentage of the flooding load on the basis

of a known efficiency versus load relationship

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

of system properties only . If exceeded massive entrainment of liquid droplets

will occur .

40
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Tray Pressure Drop

Typical Tray Pressure Drop : 2.5 - 15 mbar (25 - 150 mm WC)


Usually small vis-a-vis system pressure except for vacuum columns

Tray pressure drop plays an important role in filling up downcomers.


To counter tray pressure drop, a liquid head builds up in downcomer,
to enable liquid to flow down against it.

Excessive Tray Pressure Drop : excessive liquid head and hence


downcomer flooding

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Tray Pressure Drop

The Tray Pressure Drop consists of :

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.

To a lesser extent , it depends on physical properties of the gas/liquid system.

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.
42
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Flow Regimes On Trays

Bubble Regime : gas bubbles in liquid

Spray Regime : liquid droplets in vapor

Froth Regime : vigorous bubbles in a


two-phase mobile froth

Emulsion Regime : vapor emulsified as small


bubbles in high liquid flow

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Bubble and Spray Regimes

Bubble Regime

At low vapor flowrate a set of clear bubbles moves up from the


TRAY
perforations through a relatively quiet liquid . This roughly OPERATION
occurs at velocities of ~ 0.05 m/s or lower .

Industrial columns are unlikely to be operating in this regime


and hence should not be directly scaled up from data acquired
from an experimental setup that operates in the 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 .

44
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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

At high liquid rates compared to vapor rates horizontal momentum of liquid


shears the vapor bubbles converting them to small sized bubbles emulsified in a
liquid continuous phase . This regime behaves roughly liquid-like and equations
for liquid flow such as the Francis formula for flow over a weir apply .
In industrial practice the emulsion regime is seen in columns operating under
high pressure and high liquid rates .
45
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Practical Operating Regimes

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 .

The Emulsion Regime has negligible entrainment but is prone to foaming .

Trays operate better at higher pressure in Froth compared to Emulsion regime


because the emulsion regime is characterized by significant vapor recycle.

Strictly speaking the Francis Weir formula is applicable only to the Emulsion
regime and neither the Spray nor Froth regime .

Entrainment is expectedly severe in Spray Regime as most of the liquid exists as


small droplets at some distance above tray floor . These are easily carried to
the tray above and drastically affect tray efficiency . Vacuum columns are
therefore designed with a generous tray spacing and usually >= 600 mm .
46
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Performance Parameters

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.

Weir Load or Volumetric Liquid Rate per Unit Length of Weir

QL / LW

It is a primary parameter for determining the liquid head on a tray which is a


component of pressure drop and downcomer backup . At rates above 4 gpm/in (35
m3/h/m) it also influences jet flood capacity .

Superficial Downcomer Velocity

QL / Adc

Although the flow in a downcomer is primarily two - phase , superficial velocity


based on net clear liquid rate is a useful concept for orientation and preliminary
sizing .
As against the weir load which is a tray liquid loading term the superficial downcomer
velocity is purely related to downcomer liquid loading .
48
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Performance Parameters – contd.

Weir Load and Number Of Flow Paths :


Important to tray layout when liquid head on tray is important or jet flood is
governing and the weir load is high . Desirable to stay below 8 to 10 gpm/in (70 to
90 m3/hr/m) of weir . Weir load is reduced by splitting the liquid flow into two or
more paths . Swept-back weirs reduce the effective weir loading by about 10 %

Length and Number Of Flow Paths :


Experiment and industrial experience show that efficiency increases with length of
flow paths at similar weir load and vapor rate . Number of Flow paths should be
minimized and increased primarily to increase capacity for a given diameter under
downcomer limiting conditions . Great care is needed to balance the flow between
tray panels with three or more passes . Unequal L/V among the panels will harm
both efficiency and capacity . In addition , a minimum flow path of 16 inches (400
mm) is frequently used to allow for manways

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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-

impingement or anti-jump baffles are used in such cases . In general downcomer

area is ~ 5 to 10 % of column area . Minimum downcomer widths should be around

150 mm for side and 200 to 300 mm for center and off – centre downcomers .
50
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System Derating Factors

System Factor : Service System Factor


CO2 Absorber 0.80
This empirical derating factor reduces predicted capacity CO2 Regenerator 0.85
of the tray (increases % flooding, downcomer froth Caustic Wash 0.65
backup and reduces maximum downcomer inlet velocity) Caustic Regenerator 0.60
to account for a known foaming system. A value of 1.0 represents Sour Water Stripper 0.60
a non-foaming system while a lower value, 0.85 for example, Alcohol Synthesis 0.35
represents a moderately foaming system. A lists of general Hot Carbonate Contactor 0.85
foam factors as well as several specific recommendations are Hot Carbonate Regenerator 0.90
included below. Absorbers >0 *F 0.85
Absorbers<0 *F 0.80
Amine Contactor 0.73
Vacuum Towers 0.85
GENERAL FOAMING Amine Regenerator 0.85
H2S Stripper 0.90
Classification Foam Factor Furfural Fractionator 0.85
Top Section DeC1, DeC2 0.85
Non-Foaming 1.0
Glycol Contactor 0.50
Low 0.9 Glycol Still 0.80
Moderate 0.75
High 0.6

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Summary Of Design Guidelines

Recommended Range Of Operating Parameters (SI Units)


Item Minimum Value Maximum Value
Useful Capacity, % 10 95
% Flood 10 85
System Limit, % 0 90
Weir Loading, l/s/m 1.5 32
D.C. Froth Backup, % 5 90
D.C. Head Loss, mm 2.5 38
Dry Drop, mm H2O 7.6 76
Pressure Drop, mbar 3.3 20
Open Area, % 4 15
D.C. Velocity, % 0 80
D.C. Velocity, m/sec 0.0 0.137
VSF/VSF min 0.9 None
Min Flow Path, mm 406 None
Valve Density, #/m2 301 344
Spray Factor 2.78 None

52
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Summary Of Design Guidelines - continued

Recommended Range For Various Hardware Parameters :

Hole Area : For most pressure services 8 to 10 percent is optimum . If pressure


drop or downcomer backup is limiting upto 15 percent is used . Hole areas more
than this are not used as they are likely to be associated with high weeping rates .

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 .

Tray Thickness : A thickness of 2 mm is commonly used . Thicker trays up


to 3 mm are used commercially for reasons of structural strength , fouling and
corrosion . For the same hole size a thicker tray has a lower pressure drop , but a
higher weep rate and lower efficiency .

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

Tray Spacing : Affects capacity and entrainment , but not turndown . Is


often varied in different zones to minimize column height after allowing for varying
loads . Most common is 24 inches (610 mm) , 12 to 18 inches (300 to 450 mm)
also used .

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 .

Downcomer Outlet Clearance : When downcomers seal is lost blowing can


occur . Therefore at low liquid rates and startup , downcomer clearances are
specified with a positive seal ~ 10 mm , less than the outlet weir height . In very
high liquid rates zero or even negative seals are used . In low liquid rates where
blowing may be serious , inlet weirs or sumps should be considered .
54
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Tray Efficiency

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

gaining ground on the stage method, as its reliability is increasing.

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.

Non-uniform flow distribution and stagnant zones reduce tray efficiency


Lower Surface tension increases the interfacial area and hence efficiency. Liquid
viscosity effect on tray efficiency is not clearly known in distillation. In absorption
mass transfer could be controlled by liquid phase mass transfer.
Many questions and unknowns remain :

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

4) Estimation of the contribution of liquid phase mass transfer resistance

5) Influence of the two phase flow regime.

Estimation of distillation tray efficiency is marked by uncertainties and inaccuracies.


Hence, confidence in the validity of available data is important.

Being of considerable commercial value the data is not available publicly.

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Typical Practical Tray Efficiencies

COLUMN TYPE TYPICAL ACTUAL TYPICAL EFFICIENCY, %


TRAYS
ABSORBER/STRIPPER 15 – 25 20 – 30
SIDE STRIPPER(STEAM) 4–6
SIDE STRIPPER(REB) 6–8
REBOILED ABSORBER 25 – 40 45 – 55
DEETHANIZER 30 – 35 65 – 70
DEPROPANIZER 35 – 40 70 – 80
DEBUTANIZER 38 – 45 85 – 90
NAPHTHA SPLITTER 30 – 35 80 – 90
C2 SPLITTER 110 – 130 80 – 100
C3 SPLITTER 200 – 250 80 – 90
C4 SPLITTER 70 – 80 85 – 90
AMINE CONTACTOR 20 – 24 -
AMINE ABSORBER 20 – 24 -
CRUDE COLUMN 35 – 50 30 – 75

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About Fractionation Research Inc. (F.R.I.)

“.. Fractionation Research Inc. : is a non-profit body supported by


members .

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 .

Members benefit using F.R.I. rating programs, database, handbooks , reports.

FRI collects , interprets , analyzes, and presents data at membe rs’ meetings,

and in Progress Reports and Topical Reports.

The Data models enable practicing engineers of member companies select and

design cost effective fractionation equipment with a high chance of success.

F.R.I.'s facility is the primary independent test forum for new fractionation

equipment to validate improvement claims relative to standard equipment..”


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FRI Member Companies

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

Active Area : where mass-transfer occurs

Downcomer : transports liquid tray to tray

Free Area : for vapor-liquid disengagement

FREE AREA Ability to mix , then separate vapor and

liquid limits tray capacity.

The area under the entering downcomer and

over exiting downcomer where liquid and vapor

cannot mix on tray deck. This inactive area

is what high-capacity trays attempt to


Operation Of A Standard Tray use.

61
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High Capacity Trays – contd.

Objective :
Increase capacity of Internals without changing the Column

Improvements Are Made By

Increase active area by using hanging downcomer


Using smaller valves or sieve holes
Directional valves

Each option has unique operating characteristics


UOP MD Tray
NYE tray ( Koch-
Koch- Glitsch)
Vortex Tray ( Sulzer )
Swirl Tube ( Shell + Sulzer)
Flexitray ( Koch-
Koch- Glitsch)
MVG tray ( Sulzer)
Super Frac(Koch-
Frac(Koch- Glitsch)
Ultra Frac(Koch-
Frac(Koch- Glitsch)

62
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Truncated Downcomer Tray

Side Downcomers Truncated


at some distance above the
usual tray level

This area is now free for


vapor from below to make
use of for vapor-liquid
contact on the tray
In a similar fashion area
area under the Center
Downcomer is freed for
vapor-liquid contact on tray

Isometric View of a Schematic of flow of


Two-Pass tray with vapor and liquid on a
Truncated Downcomers Truncated Downcomer Tray

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Vapor Flow Promoter

The slotted area under the downcomer is equipped


with special valves to direct vapor flow uniformly .
These special flow promoting devices are arranged
at the inlet to tray panel and also along the flow
path length

Directed vapor promotes well – distributed fluid flow


all over the tray panel and minimizes stagnant
pockets . The overall efficiency of the tray is
significantly improved .

Flow Promoting Device


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Downcomer Sealing

Careful design of downcomers and downcomer slot sizing is critical for


a high capacity tray design .

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Vapor Crossflow Channelling

Flow Promoting Device

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Sieve Tray Design

To Design A Sieve Tray


1. Calculate the column diameter that prevents flooding
2. Design the tray layout
3. Design the downcomers

Use Fair's Procedure


1. Estimate vapor velocity causing flooding due to excessive entrainment.
2. Uses a rule of thumb to determine the operating velocity
3. Calculate column diameter
4. Calculated to allow vapor velocity that will prevent excessive
entrainment
5. Method applicable to sieve, valve, and bubble cap trays.
6. Flooding velocity, U flood

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Fair’s Correlation for Sieve Tray Jet Flood Prediction

Fair’s Correlation :the earliest available u ρ L - ρ V


= K
ρ
flood
for design of Sieve Trays V

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

Flow Parameter Flv is calculated based on Csb, f


the vapor–liquid load and densities .
For a given Tray spacing the value of Csb,f
Capacity Factor at Flood is determined

Once the capacity factor at flood is known


the vapor velocity at flood is calculated
Design vapor velocity = 0.75 - 0.85 U W ρ
flood
L v
F =
ρ
LV

68
W V L

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Column Diameter

• Tray Spacing Selected According To Maintenance Requirements


• Tray Spacing 10" to 36" ( 12" - 16" common for small towers < 5 ft)
• Spacing usually greater in large diameter columns
• 18" min with 24" typical to have a worker crawl through column for
inspection
M V
u op =
• Operating Vapor Velocity = ρ A (3600)
v net

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

• If large changes in vapor velocity in


column Calculated diameters can be quite
different at different sections

If column with single diameter is constructed,


- efficiencies in different parts of the
column may vary considerably
- need to include in design calculations

• Maximum diameter close to one of


these
1. Diameter at the top
2. Diameter at the bottom
3. Diameter above the feed
4. Diameter below the feed

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Sieve Tray Layout And Tray Hydraulics

Holes are arranged in a pattern with sizes ranging

from 1/8" to 1/2” :


Fouling Applications : holes are ~ 1/2" or larger

Clean Service : ~ 3/16" is reasonable

Common Tray Layout :


2 - 3"
2-3"
– equilateral triangular pitch Weir
3-5"
– holes are spaced 2.5 to 5 do Inlet Outlet
Downcomer Downcomer
– region containing holes is at minimum 2 to 3“ do

– clearance from column shell and inlet downcomer 2.5 - 5


do

– 3 to 5" minimum clearance is used before the


downcomer

– weir to allow disengagement of liquid and vapor

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Sieve Tray Layout and Tray Hydraulics

Prevention Of Downcomer Flooding


– Downcomers designed on basis of pressure drop
and liquid residence time
– Costs are relatively small
– design done only in final equipment sizing

Pressure Heads In Sieve Trays


h dc = head of clear liquid in downcomer
h ∆p
hdc = h∆p + hweir + hcrest + hgrad + hdu hdc h hgrad
du hcrest
hweir

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Sieve Tray Layout and Tray Hydraulics

hcrest = height of liquid crest over the weir

Francis Weir Equation


hcrest = C F weir (Qg/Lweir )2/3
C is a proportionality constant specific to the system of units and
F weir is a factor to account for the curvature of column in the downcomer
Large columns => lweir is large , F weir approaches 1.0

• H grad - liquid gradient across the tray


– sieve trays, it is often very small => usually ignored
• H du - frictional loss due to flow in the downcomer and under the
downcomer onto the tray.
2
h du = C Q l 
 A du 
A du = flow area under the downcomer apron in ft2
downcomer apron typically has 1 inch gap above the tray
A du = (gap) Llweir

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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

• Therefore, in normal operation tray spacing > 2h dc i.e. φ dc = 0.5

• Downcomer designed to give a liquid residence time of ~ 3 to 7 sec.

Valve Tray Design


Sieve tray design procedure used as a basis and then modified as necessary.

Sieve vs valve => major difference is pressure drop characteristics

ρV v 2o
valve h∆p ,valve = K v
ρ L 2g
vo - velocity of vapor through the holes in the deck, ft/sec

K v ,closed = 33 K v ,open = 5.5

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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.

75
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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

Care should be taken to increase the


tray spacing at sections where there
are feed and reflux entry nozzles and
attachments , or any other internal
obstructions that could interfere with
vapor – liquid disengagement .
The general rule of thumb is to add the
largest diameter of entering pipe to the
normal tray spacing .
It should be noted that a simple opening
Increase Tray Spacing
on the shell without any insertion , such
At Feed Locations
as that due to a manhole , does not
warrant this increase

Failure to adequately account for interfering internals in the inter-tray spacing


could result in an avoidable localized capacity bottleneck and sometimes a
catastrophic failure in performance .

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Some Additional Practical Design Aspects

Whenever part of the liquid flowing down


a tray needs to be taken out of the
column a drawoff sump is required .
The sump has to be sized to avoid
excessive velocities in the direction of
the nozzle . Such velocities result in
buildup of liquid level on the tray and
subsequent maldistribution . Sump of Sufficient Size To Provide
Required Flow to Nozzle
Thus , a bottleneck introduced on the
tray and insufficient liquid draw means
deterioration of column performance .

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

Chimney Trays are convenient devices for providing


residence time and supply liquid to drawoff nozzles .
They also serve as vapor and liquid redistributors.
The vapor risers of chimney trays should be properly
sized for efficient operation .
Sufficient space must be provided at the vertical
curtain where the vapor emerges out of the riser .
Likewise , the top of the riser should be sufficiently
raised above the outlet weir so that there is no
liquid bypassing down the riser .
A clear gap of 450 mm minimum is usually provided
between the top of the riser cap and the bottom of
the tray above for uniform vapor distribution . Chimney Tray Spacing
For Liquid Drawoff
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Comparison Of Packings And Trays

When pressure drop has to be minimised such as in vacuum applications


Structured Packing has no comparison . Trays have the highest pressure
pressure drop and
hence are unsuited for vacuum service .
Foaming services are best handled by packings rather than trays .
When column diameter is small it is not feasible to install the usual trays and
only expensive cartridge trays are the option . In this case either
eit her random or
structured packing is the better option .
For corrosive applications the choice of tray metallurgy is limited whereas in
packings ceramic and plastic are feasible options . Trays of exotic
exotic metallurgy can
be prohibitively expensive .
Liquid holdup significantly lower for random and structured packings as
compared to trays . Hence for polymerizing and explosive material
material where
inventory has to be minimized packing is the obvious choice .
Solids can easily foul packing whereas trays are relatively unaffected and hence
chosen .

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Comparison Of Packings And Trays – contd.

High liquid rates can drastically reduce structured packing performance in


particular due to channel blockage whereas multi-pass trays can easily handle
high liquid loads .
When column diameters are large packings suffer from mal-distribution and
hence precious space is lost in having a redistribution arrangement once every
few meters . Trays do not suffer from such limitations and hence cost can be
minimised .
For complex columns with multiple feed and draws it is much easier to
take a tapping from a tray column whereas for a packed column it usually has
to be either at the top or the bottom of a packed bed only and not anywhere
in between .
Feed point and product draw options can be incorporated much more easily
and at multiple locations in a tray column whereas such flexibility is limited in
packed bed columns .
Weight and consequently cost of a tray column is lower than that of a
comparable packed column . However the tray column is likely to be taller and
the savings on the cost of internals are slightly offset by the increase column
costs .

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Benefits to Business Units Of Detailed Technical Analyses Of Columns
And Internals

1) The Design is freed of various cluttered , and often vague , safety


factors .
2) Gross errors and assumptions in the design basis , if any , are
identified , and future shocks prevented .
3) A smarter design lends itself to smarter costing , and a more
competitive bid .
4) Other cost factors such as nozzle and piping sizes , which are
significant in case of SS or exotic metallurgy , are also addressed
along with the checking of the general arrangement of the column .
The correct estimation of these adds to the overall accuracy of
competitive bidding .
5) A column that is more thoroughly designed upfront is less likely to get
into trouble once it enters the hectic project execution stage .

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Shoot your questions !!

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Brief Introduction Of Speaker

K . Jayanth Pai

Educational Qualifications

B.Tech, Chemical Engg. (1988) I.I.T. Delhi

M.Tech, Process Engg. & Design (1992) I.I.T. Delhi


Work Experience :
After graduation in 1988 , worked in various industries and in varied
functions such as Production , Projects , Research and Development ,
Technical Services , and Design Engineering .
Before joining L&T in June 2004 was with Sulzer Chemtech at Pune in the
Technology Group .
At L&T working as Head of the Chemical Engineering Group in the
Technology and RND Department , and responsible for High-end technical
support to various Business Units on varied aspects of Process Simulation ,
Design , Troubleshooting , and Project & Proposal Engineering
. 85
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