CHE 306

Chapter 4: Binary Column Distillation:

Internal Stage-by-Stage Balances
Dr. Sagheer Onaizi
 DISCLAIMER!
 The materials presented in lecture
presentations are only summaries of the text
materials
 The material covered in these presentations
can be incomplete
 Students will be examined according to the
text materials presented in the textbook and
handouts
2
 Internal Balances
 External balances is NOT enough for column design
and product specification problems, and, therefore,
internal stage-by-stage balances are required
 We can start doing the stage-by-stage balances either
from the top (i.e., stage 1) or from the bottom (i.e.,
reboiler). Usually:
 Start at the top
 Write balances and equilibrium relationships for
first stage
 Determine unknown variables for the first stage
 Write balances and equilibrium relationships for
second stage utilizing variables that were just
computed for the first stage
 Proceed down the column in a stage‐by‐
stage fashion until you reach the last stage 3
 Rectifying Section: Stage
1 Balances
If partial condenser is used,
 Assumptions: it acts as an equilibrium stage
 In each stage, vapor and liquid phases are in
equilibrium with each other
 In each stage, T and P are constant
Condenser
 Overall mass balance:
V2  L1  D

 Species balance (for more volatile

component):
y2V2  x1 L1  xD D

Energy balance:
H 2V2  QC  h1 L1  hD D

4
 Rectifying Section: Stage
1 Relations
 Assumptions:
 Vapor phase is saturated vapor If partial condenser is used,
 Liquid phase is saturated liquid it acts as an equilibrium stage

 In each stage, vapor and liquid phases

are in equilibrium with each other.
Condenser
Accordingly:
h1  h( x1 ) and H 2  H ( y2 )

 Mole fractions of vapor phase and liquid

phase leaving each stage are proportional
x1  x1 ( y1 )
to each other, as follows:
5
 Rectifying Section:
Stage 1 Solution
V2  L1  D y2V2  x1 L1  xD D
If partial condenser is used,
it acts as an equilibrium stage

H 2V2  QC  h1 L1  hD D Condenser

 There are:
 6 unknowns (L1, V2, x1,
y2, H2, h1)  4 knowns
 To find the unknowns, we  xD specified
need:  P specified
 D calculated from external mass
 6 equations balance
 Solve the equations to  QC calculated from external energy
balance
determine the unknowns 6
 Rectifying Section: Stage 2 Balances and
Relations
 Overall mass balance:
V3  L2  D If partial condenser is used,
it acts as an equilibrium stage

 Species balance (for more volatile

component): Condenser

y3V3  x2 L2  xD D
 Energy balance:
H 3V3  QC  h2 L2  hD D

 Relations
h2  h2 ( x2 ); H 3  H 3 ( y3 ); x2  x2 ( y2 ) 7
 Rectifying Section: Stage 2
Solution
V3  L2  D y3V3  x2 L2  xD D If partial condenser is used,

H 3V3  QC  h2 L2  hD D
it acts as an equilibrium stage

 There are: Condenser

 6 unknowns (L2, V3, x2, y3, H3, h2)

 To find the unknowns, we need:

 6 equations
 Solve the equations to determine
the unknowns
8
 For any Stage (j) Above the Feed
Stage: Balances and Relations
V j 1  L j  D
If partial condenser is used,
 Overall balance: it acts as an equilibrium stage

 Species balance (for more volatile Condenser

component): y j 1V j 1  x j L j  xD D

 Energy balance:
H j 1V j 1  QC  h j L j  hD D

 Relations
h j  h j ( x j ); H j 1  H j 1 ( y j 1 ); x j  x j ( y j )
9
 Rectifying Section: Stage J
Solution
y j 1V j 1  x j L j  xD D
If partial condenser is used,
V j 1  L j  D; it acts as an equilibrium stage

H j 1V j 1  QC  h j L j  hD D Condenser

 There are:
 6 unknowns (Lj, Vj+1, xj, yj+1, Hj+1, hj)

 To find the unknowns, we need:

 6 equations
 Solve the equations to determine
the unknowns 10
 Stripping Section: Stage f+1 Balances and Relations

 Feed stage is f; the stage just below the feed

stage is f+1
Overall balance: V  L B
f 1 f

Species balance (for more volatile component):

y f 1V f 1  x f L f  xB B
Energy balance:
Reboiler
h f L f  QR  H f 1V f 1  hB B
A partial reboiler acts as an equilibrium stage
Relations:
h f  h f ( x f ); H f 1  H f 1 ( y f 1 ); x f  x f ( y f ) 11
 Stripping Section: Stage f+1 Solution

 There are:
 4 knowns
 xB specified
 P specified
 B calculated from external mass
balance
 QR calculated from external energy
balance
 6 unknowns (Lf, Vf+1, xf, yf+1, Hf+1, hf) Reboiler
Need: 6 equations A partial reboiler acts as an equilibrium stage
 Solve the equations to

determine the unknowns 12

 For any Stage (k) Below the Feed
Stage: Balances and Relations
Overall balance: V k  L k 1  B

Species balance (for more volatile

component):
yk V k  xk 1 L k 1  xB B
Energy balance:

H k V k  hk 1 L k 1  QR  hB B Reboiler

Relations A partial reboiler acts as an equilibrium stage

hk 1  hk 1 ( xk 1 ); H k  H k ( yk ); xk 1  xk 1 ( yk 1 ) 13
 Stripping Section: Stage k Solution

 There will be:

 4 knowns:
 xB specified
 P specified
 B calculated from external mass
balance
 QR calculated from external energy
balance
Reboiler
 6 unknowns (Lk-1, Vk, xk-1, yk, Hk, hk-1)
 6 equations A partial reboiler acts as
 Solve the equations to determine the an equilibrium stage

unknowns x N 1  xB 14
 Problem is finished when:
 Binary Stage-by-Stage
Solution Methods
 We need to solve 6 equations (3 balance
equations + 3 equilibrium relationships)
simultaneously
 This can be done by
 Trial and error (Sorel method)
 Graphical method (Ponchon and Savarit method)
 Approximate analytical solution was
developed by Lewis

15
 Lewis Method (1)
 To apply Lewis method, the
following assumptions have to be
made:
 The column is adiabatic
 The enthalpy changes between adjacent stages are
small compared to the latent heat changes
H j 1  H j   and h j 1  h j  

 The heat of vaporization per mole, λ , is relatively

constant throughout the column
 Lewis called the above three
assumptions (conditions) 16
constant molal overflow (CMO).
Validity of the Assumptions

17
Ethanol-Water System

18
 Lewis Method (2)
 If these three assumptions (especially, the third
one) are valid, then:
Enriching L1  L2  L3   L j   L f 1  L
Section
V1  V2  V3   V j   V f 1  V

Stripping L f  L f 1   L k 1   L N  L
Section
V f V f 1   V k 1   V N  V
 NOTE that:

LL and V V 19
 If the CMO Assumption is
Valid: Enriching Section
In this case: H j 1  H j and h j 1  h j
V j 1  L j  D  D  V j 1  L j

y j 1V j 1  x j L j  xD D  x j L j  xD V j 1  L j 
Lj  Lj 
y j 1  x j  1   xD
V j 1  V 
 j 1 

L  L
y j 1  x j  1   xD
V  V
This is the operating line for the enriching section
 If the CMO Assumption is
Valid: Stripping Section
In this case: H k 1  H k and hk 1  hk
L k 1  V k  B  B  L k 1  V k


yk V k  xk 1 L k 1  xB B  xk 1 L k 1  L k 1  V k xB 
L k 1  L k 1 
yk  xk 1    1 xB
Vk  Vk 

L  L
yk  xk 1  1   xB
V  V
This is the operating line for the stripping section
 Balances Around the Feed
h F  H V  hL  h L  HV
Stage (1) h F  H V  V   hL  L
F

F V  L  L V
hF F  H f 1V  h f 1 L  h f L  H f V
 Recall this assumption: The enthalpy
changes between adjacent stages are small

H f 1  H f and h f 1  h f

hF F  (V  V ) H  ( L  L)h

hF F  ( L  L  F ) H  ( L  L)h   
hF F  H L  L  FH  h L22 L 
 Balances Around the Feed
Stage (2)
( H  hF ) F  ( L  L)( H  h)
Feed quality
L  L H  hF
q 
F H h
L  L  qF and V  V  (1  q ) F  V  V  (1  q ) F
liquid flow rate below feed stage  liquid flow rate above feed stage
q
feed flow rate
vapor enthalpy on feed stage  feed enthalpy
q
vapor enthalpy on feed stage  liquid enthalpy on feed stage

If feed is saturated vapor (q=0), saturated liquid (q=1)

23
or a two-phase mixture (0<q<1)
 Example 4-1. Stage-by-stage
calculations by the Lewis method
A steady-state countercurrent, staged distillation column is to
be used to separate ethanol from water. The feed is a 30 wt
% ethanol, 70 wt % water mixture that is a saturated liquid
at 1 atm pressure. Flow rate of feed is 10,000 kg/h. The
column operates at a pressure of 1 atm. The reflux is returned
as a saturated liquid. A reflux ratio of L/D = 3.0 is being used.
We desire a bottoms composition of xB = 0.05 (weight fraction
ethanol) and a distillate composition of xD = 0.80 (weight
fraction ethanol). The system has a total condenser and a
partial reboiler. The column is well insulated. Use the Lewis
method to find the number of equilibrium contacts
required if the feed is input on the second stage from the
top. 24
Ethanol-Water Equilibrium
Curve

25
 Solution (1)

From external mass balances D = 3333.3 kg/h and B = 6666.7 kg/h 26

Solution (2)

27
Solution (3)

28
Solution (4)

29
 Introduction to the
McCabe-Thiele Method
 It is a graphical method
based on Lewis’s method
and the fact that the two
operating lines are straight
lines on the y‐x diagram
 Used for binary systems
 You need to solve the
equilibrium relationship from
the y‐x equilibrium curve and
the mass balance from the
L  L
operating lines. y j 1  x j  1   x30D
V  V
 McCabe-Thiele Procedure:
Enriching Section (1)
D will be specified or can be calculated from external balances
Find L0 and V1
L0  RD and V1  L0  D  D( R  1)
From the CMO assumption

Pl
xD will be specified

ot
op
xD  x0  y1

era
tin
gl
From equilibrium relationship find:

in e
y1 L R

D x1 V R 1
x0 L  L
From enriching operating line: y j 1  x j  1   xD find:
V  V
y2 Proceed to stage 2
31
 McCabe-Thiele Procedure:
Enriching Section (2)
x1 and y 2 are alreday specified from equilibrium curve and operating line for stage 1
From equilibrium curve find:
x2
L  L
From y j 1  V
x j  1   xD find:
 V
y3
L R

V R 1
Proceed to stage 3
Stepping down the stages in the
rectifying (enriching) section
using McCabe-Thiele method

32
Continue to the last stage in the enriching section
 McCabe-Thiele Procedure:
Stripping Section (1)
B and x B will be specified or can be calculated from external balances
Since:
xB  x N 1
From the equilibrium curve, find:
y N 1
L  L
From stripping operating line: yk  xk 1  1   xB find:
V  V
xN
Stepping down the stages in the
stripping section using McCabe-
Proceed to stage N Thiele method

L  L
yk  xk 1  1   xB
V  V  33
Continue to the last stage in the stripping section
 L0 z  xB 
F  qF
McCabe-Thiele Procedure: L

D x D  x B 
Stripping Section (2) V L0 z  xB  F  qF  xD  z  F
D x D  x B  x D  x B 
L Since:
How to obtain ?
V F  DB
We have: zF  xD D  xB B
L  L H  hF z  xB
D F
q  xD  xB
F H h x z
B D F
xD  xB
L  L  qF
L0
Since V  L  B L0  RD  R
D
L L  qF Now, you

V L  qF  B can plot
L0
L
z  x B   q x D  x B  the stripping
 D operating
V L0 z  x   qx  x   x  z  line
L  L B D B D
yk  xk 1  1   xB D 34
V  V
 McCabe-Thiele: Whole Column (1)

 The number of steps or staircases from x D

to x B = the number of stages of the

distillation column
 In the adjacent figure, stage # 3 is the feed
stage
 The intersection between the top and
bottom operating lines is within the feed
stage (when the optimum feed stage is
35
used)
 McCabe-Thiele: Whole Column (2)

The feed stage is

NOT necessarily be
the stage at which
there is an
intersection between
the top and bottom
operating lines
Feed stage = # 2
Feed stage = # 5
36
 y j 1V  x j L  xD D
Feed Line (1)
yk V  xk 1 L  xB B
Mass balance in the enriching section Mass balance in the stripping section
on the more volatile component: on the more volatile component:

yV  Lx  D xD Top Op line
yV  Lx  BxB
Bottom
At the intersection of the above two equations: Op line

ytop , op  ybot , op and xtop , op  xbot , op

   
y V  V  L  L x  DxD  BxB 
V  V  VF Fz  DxD  BxB 
LF F
L  L  LF y x z
VF VF 37
 Feed Line (2) y
LF
x
F
z
VF VF

Fraction of feed vaporized (f): Feed line

f  VF / F f 1 1
y x z
LF / VF  ( F  VF ) / VF  (1  f ) / f f f
Fraction of remaining liquid (q):
q  LF / F q 1
y x z
LF / VF  LF /( F  LF )  q /(1  q ) q 1 1 q
F / VF  F /( F  LF )  1 /(1  q)

LL F
F V  L  V  L V  V  F  ( L  L) y x z
F  ( L  L) F  ( L  L)

38
 Feed Line (3)

TF: Feed Temperature

TBP: Bubble Point Temperature L  L H  hF
TDP: Dew Point Temperature q 
F H h
 Optimal Feed Stage
The optimal feed stage is the one
that makes:
y f 1  y I  y f and x f  xI  x f 1

 (q  1)(1  L / V ) xD  z
xI 
(q  1)( L / V )  q
L  L
y I  x I  1   x D
V  V

The intersection of the enriching

and stripping operating lines MVC = more volatile component 40
 Example 4-2 (1)
Calculate the feed line slope for the following cases.
a. A two-phase feed where 80% of the feed is vaporized under column
conditions.

41
 Example 4-2 (2)
b. A superheated vapor feed where 1 mole of liquid will vaporize on
the feed stage for each 9 moles of feed input.

42
 Example 4-2 (3)
c. A liquid feed subcooled by 35°F. Average liquid heat capacity is 30
Btu/lbmol°F and λ = 15,000 Btu/lbmol.
 Example 4-2 (4)
d. A mixture of ethanol and water that is 40 mol% ethanol. Feed is at
40°C. Pressure is 1.0 kg/cm2.

The enthalpy data are available in Figure 2-4. To use that figure we must convert to
weight fraction. 0.4 mole fraction is 0.63 wt frac. Then from Figure 2-4 we have
hF(0.63, 40°C) = 20 kcal/kg
From Figure 2-4 H (0.63, satd vapor) = 395, h (0.63, satd liquid) = 65 kcal/kg, and

Since all the molecular weights are at the same concentration, they divide out.

44
Figure 2-4

45
 Summary of McCabe-Thiele
Method
L  L Enriching Section:
y y  x  1   x D Operating line
1 V  V Slope=L/V=R/(R+1)<1
Equilibrium  q   1  Feed line
2 y    x    z
curve
yN  q 1   1 q 
Stripping Section:
3 L  L
y  x  1   xB Operating line
Slope= L / V = (VB+1) /VB
yB V  V
4 45° line q>1
q=1

0<q<1 L L*
L+V x=y
xB x=zF xD
LL
q
Step 1: Plot equilibrium curve and 45° line. q=0 V F
H  hF
Step 2: Locate z, xD and xB on the 45° line 
V* H h
Step 3: Draw OL for Rectifying section q<0
Step 4: Draw OL for Stripping section
Step 5: Draw the q-line 46
Step 6: Determine the number of stages
 Complete McCabe-Thiele
Method
 Example 4-3. McCabe-Thiele method
A distillation column with a total condenser and a partial reboiler is
separating an ethanol-water mixture. The feed is 20 mol%
ethanol, feed rate is 1000 kmol/h, and feed temperature is 80°F.
A distillate composition of 80 mol% ethanol and a bottoms
composition of 2 mol% ethanol are desired. The external reflux
ratio is 5/3. The reflux is returned as a saturated liquid and
CMO can be assumed. Pressure is 1 atm.

Find the optimum feed plate location and the total number of
equilibrium stages required.
47
 Solution (1)

In Example 4-1 we showed that CMO is

valid. Thus we can apply the McCabe-
Thiele method.
Feed Line: To find q, first convert feed
concentration, 20 mol%, to wt % ethanol =
39 wt%. Two calculations in different
units with different data are shown.

48
Figure 2-4
zF=0.39 TF=26.7 °C
 Solution (2) Points on q-line:
(0.2, 0.2) and (~0.25, 0.6)
 q   1 
y    x    z
 q  1   1  q 

Points on Top op. line:

(0.8, 0.8) and (0, 0.3)

Points on Bottom op. line:

Point 1: The bottom operating line (0.02, 0.02) and intersection
intersects the top operating line at the feed line

Point 2: The intersection of the bottom operating line

and the y = x line is at y = x = xB N = 12 +R; NF = 2 from bottom up
Configuration Changes to
be Discussed
 Replace PR with direct vapor
injection (open steam heating)
 Multiple feed
 Partial condenser
 Total reboiler
 Side streams
 Total reflux (i.e., no
distillate/bottoms products)
51
 Open Steam Heating
Example 4-4.
The feed is 60 mol% methanol and 40 mol% water and is input
as a two-phase mixture that flashes so that VF/F = 0.3. Feed flow
rate is 350 kmol/h. The column is well insulated and has a total
condenser. The reflux is returned to the column as a saturated
liquid. An external reflux ratio of L0/D = 3.0 is used. We desire a
distillate concentration of 95 mol% methanol and a bottoms
concentration of 8 mol% methanol. Instead of using a reboiler,
saturated steam at 1 atm is sparged directly into the bottom of
the column to provide boilup. Column pressure is 1 atm. The
equilibrium data are provided on the next slide.
Calculate the number of equilibrium stages and the
optimum feed plate location. 52
Solution (1)

53
 Solution (2)

 These values are not equal, and in fact, water’s latent heat
is 15.3% higher than methanol’s. Thus, CMO is not strictly
valid; however, we will solve this problem assuming the
validity of CMO.

 The configuration at the bottom of the column is different

than when a reboiler is present. Thus, we should expect
that the bottom operating equations will be different from
those derived previously.
54
 Solution (3)

Top Operating Line

 Assume CMO and solve for yj+1

 Since the reflux is returned as a saturated liquid

55
 Solution (4)

Feed Line

1-q

 Intersection: y = x = z

56
 Solution (5)

Bottom Operating Line

 Solve for y:

 Simplifications: Since the steam is pure water vapor, y s =

0.0 (contains no methanol). Since steam is saturated, S= V
and B = (constant molal overflow). Then:

57
 Solution (6)

One known point is the intercept of the top operating line

with the feed line. We still need a second point, and we can
find it at the x intercept. When y is set to zero, x = x B

58
 Solution
x x
(7)
0.28  0.08
fraction  N B
  0.9
xN  xN 1 0.28  0.06

Top Operating Line

Feed Line

Bottom Operating Line

We can plot this line between two points, the x5 = 0.06
intercept of top operating line and feed line, and x4 = 0.28

NF = 4 59
 General McCabe-Thiele
# of OLs  1  # of feeds  # of side streams
Analysis Procedure (1)
1. Draw a figure of the column and
label all known variables
2. For each section:
a. Draw a mass balance envelope.
b. Write the overall and most volatile
component mass balances.
c. Derive the operating line equation.
d. Simplify.
e. Calculate all known slopes,
intercepts, and intersections. 60
 General McCabe-Thiele
# of q lines  # of feeds  # of side streams
Analysis Procedure (2)
3. Develop feed line equations. Calculate q
values, slopes, and y = x intersections. For
operating and feed lines:
a. Plot as many of the operating lines and feed
lines as you can.
b. If needed, do external mass and energy
balances

4. When all operating lines have been

plotted, step off stages, determine optimum
feed plate locations and the total number of
stages 61
 Distillation with Two Feeds
We wish to separate ethanol from water in a distillation column
with a total condenser and a partial reboiler. We have 200
kmol/h of feed 1, which is 30 mol% ethanol and is saturated
vapor. We also have 300 kmol/h of feed 2, which is 40 mol%
ethanol. Feed 2 is a subcooled liquid. One mole of vapor
must condense inside the column to heat up 4 moles of feed 2
to its boiling point. We desire a bottoms product that is 2 mol%
ethanol and a distillate product that is 72 mol% ethanol. External
reflux ratio is L0/D = 1.0. The reflux is a saturated liquid.
Column pressure is 101.3 kPa, and the column is well insulated.
The feeds are to be input at their optimum feed locations. Find
the optimum feed locations (reported as stages above the
reboiler) and the total number of equilibrium stages
required.
Solution (1)

63
Solution (2)

64
Solution (3)

65
Solution (4)
Solution (5)

OR V '  V  (1  q2 ) F2
Solution (6)
Solution (7)
 Partial Condensers
 A partial condenser condenses only
part of the overhead stream and returns
this as reflux.
 If a vapor distillate is desired, then a
partial condenser will be very
convenient.
 The partial condenser acts as one
equilibrium contact.

70
 Total Reboilers

 A total reboiler vaporizes the entire stream sent

to it; thus, the vapor composition is the same as
the liquid composition.
 The mass balance and the bottom operating line
equation with a total reboiler are exactly the
same as with a partial reboiler.
 The total reboiler is not an equilibrium contact
and appears on the McCabe-Thiele diagram as
the single point y = x= xB.

71
 Side Streams or
Withdrawal Lines
Overall mass balance:
V '  L'  D  S
Mass balance on the MVC:
V ' y  L' x  DxD  SxS
The middle operating line
equation is:

72
 Total Reflux
Since D = 0  V=L

L  L
y x  1   x D
V  V

Simplifies to: yx

Since B = 0  V  L

L  L
y  x  1   xB
V  V
The operating line for both
sections of the column is the
Simplifies to: yx 45° line
 Minimum Reflux

The optimum external reflux ratio is between 1.05 and 1.25 times
(L/D)min. 74
End of Chapter 4

75