Acetone(10,000 kg/hr) is to be recovered from an aqueous waste stream by continuous distillation.

The
wantedand aqueous effluent must not contain more than 1 mole % acetone. The feed will be saturated l

Solution
Given Equilibrium data
x 0 0.1 0.2 0.3 0.4 0.5
y 0 0.73 0.79 0.81 0.83 0.84

1 Draw macabthile diagram and calculate number of stages and reflux ratio
2 Assuming that column efficieny of 60 % calculate the actual stages by using=Number of stages
3 Number of stages calculated= 10
4 Actual number of stages=10/0.6=17
5 Top composition= 95 mole % acetone
6 Bottom compositon= 1 mole % acetone
7 Reflux ratio=1.24
8 Calculate average molecular weight of feed=0.1*58+(1-0.1)*18=22
9 Feed Molar flow rate=Mass flowrate/Avg molecular wt=454.5kgmole/hr
10 Perform overall mass balance and calculate D,B
11 D=43.5kmole/hr, B=411kmole/hr
12 Calculate vapor rate(V), Liquid rate above feed plate(L) and liquid rate below feed plate(L')
13 V=D(1+R)=43.5(1+1.24)=97.5
14 L=RD=54Kmole/hr
15 L'=L+F=508.5kmole/hr
16 Calculation of Physical properties
17 Assume pressure drop per plate is 100mm water
18 Column pressure drop(height*density*Number of stages)=100*10^-3*1000*9.81*17=16,677
19 Top pressure is at atomspheric=101.4*10^3 Pa
20 Bottom pressure estimated=101.4*10^3+16,677=118,077 Pa=1.18 Bar
21 Finding the column diameter
22 Calculate Flv factor for top at bottom
23 Flv Bottom 0.14130807
24 Flv Top 0.02913557
25 Take plate spacing as 0.5 meter
26 From figure as send in draft calulate base K1 and Top K1
27 Correction for K1 is applied when surface tension value is either lesser or greater than 20mN/
28 New base K1 0.0930847
29 New top K1 0.0923085
30 Base Uf 3.43430004 m/sec
31 Top Uf 1.77 m/sec
32 Design for 85 % flooding at maximum flowrate
33 Base Un=3.43*0.85=2.92m/sec 2.92
34 Top Un= 1.77* 0.85=1.50 m/sec 1.5
35 Calculation of maximum vapor volumteric flowrate at top and bottom
36 At base Volumetric flow rate 0.7190957191 m3/sec
37 At top volumetric flow rate 0.732689211 m3/sec
38 Net area required at base 0.2462656572 m2
39 Net area required at top 0.488459474 m2
40 As first trial take downcomer area as 12 % of totl column cross sectional area
41 Base cross-sectional area 0.2798473378 m2
42 Top cross-sectional area 0.5550675841 m2
43 Calculate column diameter
44 Base diameter 0.5970707 meter
45 Top diameter 0.8408879 Meter
46 Using same diameter for above and below feed so we can use standard pipe of 0.9meter
47 Selection of liquid flow pattern
48 Max volumertic liq rate 0.002753178 m3/sec

49 From figure using flowrate and column diameter select the type of pass
51 Calculation of plate pressure drop
52 Dry plate pressure drop(hd)
1.Max vap veloicty through hole(Uhmax) 24.3108576 m/sec
2. Taking Ah/Ap=Ah/Aa and plate thickness/hole dia=1 calculate the value of Co(orifice coeffic
3. Co 0.82
4. hd 32.9082108 mm of liq
5. Residual head(hr) 13.2415254 mm of liq
53 Total plate pressure drop(ht) 121.14973622 mm of liq
Here 100mmwas was assumed to calculate the base pressure. The calculation can be reper
mm pe

54 Calculation of pressure loss in downcomer

1. Calculation of height of apron (hap)above the plate. This height is normally set at 5 to 1omm
hap 40

2. Area under apron(Aap) 0.0278 m2

3. Whichever area from Ad or Aap is lesser it is used for the calculation of downcomer pressur
4. Downcomer pressure loss(hdc) 1.62812246 mm
55 Backup in downcomer(hb) 197.77785868 0.197
hb should be lesser than half of the sum of plate spacing and weir height for plate spacing ass
in this case plate spacing+ weir height=500+50=550mm
Half of plate spacing+weir height=275mm
so 197 is lesser than 275 so plate spacing is acceptable
56 Check for residence time(tr) 4.774061162 Sec
This is acceptable because residence time should be always more than 3 sec for proper intera
continuous distillation. The feed contains 10 mole % acetone. Acetone of atleast 95 % purity is
The feed will be saturated liquid.

0.6 0.7 0.8 0.9 1

0.85 0.82 0.89 0.93 1

ux ratio
s by using=Number of stages calculated from mcabthile method/0.6

Base properties
1.Molecular weight=18.4 M.W
2. Vap density=0.693kg/m3 ρvb
2 3.Liquid density=944kg/m3 ρlb
ole/hr 4. Surface tension=58.9*10^-3N/meter σb

Top properties
rate below feed plate(L') 1.Molecular weight=56 M.W
2. Vap density=2.07 kg/m3 ρvt
3.Liquid density=748 kg/m3 ρlt
4. Surface tension=22.7*10^-3N/meter σt

L
0^-3*1000*9.81*17=16,677 Pa Base K1 0.075 L'
Top K1 0.09 V
8 Bar

50 Proisional Plate design

Column dia(Dc) 0.914 meter
Column area(Ac) 0.556 m2
Downcomer area(Ad) 0.06672 m2
esser or greater than 20mN/meter Net area(An) 0.48928 m2
Active area(Aa) 0.42256 m2
Hole area(Ah) 0.042256 m2

Calculate weir length from figure using Ad and Ac ratio

lw(weir length) 0.695 meter
Taking
Weir height 50 mm
ttom Hole diameter 5 mm
Plate thickness 5 mm

Check for weeping

ctional area Maximum liq rate in kg/sec 2.599
Min liq rate at 70 % turn down 1.8193
Maximum height of liq above weir(how)
Minimum height of liq above weir(how)
At minimum rate height of weir+ how min
From figure calcuate value of constant k2 using alue of hw+
ndard pipe of 0.9meter k2 30.6
Uh(min) 15.1357494 m/sec
Actual min vap velocity 11.91232
Actual min vap velocity is less than minimum so weeping ca
f pass increase the velocity
Reducing the hole area to 7 % of active area
New actual vap velocity 17.0176
This is well above the weep point
he value of Co(orifice coefficient)

The calculation can be reperated with revised estimate but the small change in physical properties will have little effect on the plate design
mm per plate is considered acceptable

Check for entrainment

is normally set at 5 to 1omm below the outlet weir height Vapor velocity(Uv)
% flooding
Using value of Flv factor bottom

ation of downcomer pressure loss From figure

ψ(fractional entrainment)
For avoiding entrainment the fracti
height for plate spacing assumed to be acceptable So this is acceptable

than 3 sec for proper interaction of liquid and vapors

 18.4
0.693
944
58.9

56
2.07
748
22.7

54
508.5
97.5

10 % of active area

using Ad and Ac ratio

 kg/sec
kg/sec
0.02503608 meter 25
0.01973778 meter 19.7
75 mm
tant k2 using alue of hw+ how

m/sec
n minimum so weeping can occur so we need to decrease the hole area to

0.029579 m2
m/sec

effect on the plate design.So 121

entrainment
1.46970185 m/sec
42.7948004 %
alue of Flv factor bottom as calcualted above and % flooding find the value of fractional
entrainment

nal entrainment) 0.0038

ng entrainment the fractional entrainment should be always less than 0.1