CHEMICAL ENGINEERING PROCES DESIGN

Assignment no 1

OCTOBER 25, 2018

IMTIAZ ALAM
D-16-CH-23
PLATE DESIGN IN A DISTILLATION COLUMN
CONTRACTORS:
Plate contractors cylendrical column in which in which plate is installed vertically. Enter the first
column of the liquid column through the tray and go down below the comer. The vapor tray in
small holes in the tray and therefore takes place in large scale column transfer. See the figure
mechanism

TERMS USE FOR TRAY AREAS:

 Total cross sectional area (AT)

 NET area (An)
 Bubbling area (Aa)
 Hole area (Ah)
TYPES OF PLATES:
Gas and liquid flow across the tray may be cross or counter flow and the three main types of
cross flow plates are used
1. Bubble cap
2. Valve tray
3. Sieve tray
A small introduction to plates,,

BUBBLE CAP TRAY:

A bubble cap tray used a riser also called chimney fixed to the tray through a hole and a cap
mounted over riser.The gas flows up the tray through the riser directed downward by the cap
through the annular space between riser and cap .High turn down ratio of bubble cap and a
number of slots that can help gas to disperse.
v

VALVE TRAY:
Valve trays are the modified form of sieve tray relatively large perforation are covered by
movable cap .The very common hole dia 45mm to 155 mm .The vale lift up as the vapor flow
rate increases and get down when vapor rate decreases .Valve tray provide good vapor liquid
contact at low flow rates.
SIEVE TRAY:
The sieve tray is perforated metal plate .The hole dia from 1.6 to 26 mm is commonly used .The
gas flows upward through perforation and disperse in the liquid .There is no liquid seal in case
of trays which causes weeping at low flowrates therefore low efficiency and turn down ratio.

HOW TO SELECT TRAY TYPE:

On the basis of below chart we can understand how to select tray for a column.

EFFECT OF VAPOUR FLOW ON TRAY DESIGN:

FLOODING:
The excessive vapor buildup up inside the column leading to a flooding .The nature of flooding
depend upon the column pressure and liquid to vapor flow rate.
Flooding condition can b estimated by fairs correlation.
 Unf = Csbf ( 0*/20 )*0.2 ( pt-pv/pv )*0.5

 Pv= vapor density

 Pt= liq density
 0*= liq surface tension

SIEVE TRAY WEEPING:

Weeping occurs at low flow rates. At low vapor flow rates liquid start to leak through
perforation. When none of the liquid reaches the down comer at extrema weeping
condition at low vapor flow rates, it is called dumping. The tendency of weeping
increases with hole area and vapor flow.
The minimum vapor velocity at the weep point.

Umin = k2-0.9(25.4-dh)
Pv*

Where.

 Dh= hole dia

 Pv= vapor density
 K2= constant of weep point depend upon (weir crest + weir height)

Weir crest can be determined by francy equation

Hwc = 750 (lwc/lwpt)*2/3

Where.

 Lwc= weir length

 Pt= liq density
 Lw= liq flow rate

LIQUID ENTRAINMENT:
Entrainment is the phenomena in which liquid droplet are carried by the vapors to the
tray above. Therefore less volatile liquid component from bottom product are mixed
with liquid relatively more volatile.
 THE PARAMETERS:
TOTAL PLATE PRESSURE DROP:

Ht = hd + (hwc +hw) +hr

Where,
 Ht=
 Hd= dry plate pressure drop
 Hwc= height of liq over weir
 Hw= weir height
 Hr= residual head

DRY PLATE PRESSURE DROP:

Dry plate pressure drop occur due to friction within dry short holes.
Can be calculated

Hd = 51 (Umax/co)*2 pv/pt

RESIDUAL PRESSURE DROP:

The residual pressure drop result mainly from surface tension as the gas release from
perforation.

hr = 12.5*10*3
pt

DOWNCOMER BACKUP (hp) AND RESIDENCE TIME:

Hb = (hwc + hw) + ht + hdc

PLATE DESIGN CONSIDERATION:

 COLUMN SIZE APPROX:
Tower diameter, m Tray spacing, mm
1 or less 500 (150 mm is minimum)
1-3 600
3-4 750
4-8 900

COLUMN DAIMETER:
The column dia is determined from flooding correlation for a chosen plate spacing. A high vapor
velocity is needed for high plate efficiency and velocity will normally be between 75 to 95 per of
that which could cause flooding.

HOLE DIA, HOLE PITCHAND PLATE THIKNESS:

The plate dia from 4 to 13 mm used. The bigger sizes causes weeping. The center to center
distance between to adjacent holes is called hole pitch. Plate thickness varies from 0.3 to 1.3
times of hole dia.

WEIR HEIGHT, WEIR LENGTH:

The depth of liquid on the tray is maintained by installing a vertical flat plate, called weir.
Height. But it increases plate pressure drop, and weeping tendency. Weir heights from 45 to 95
mm are used. For vacuum operation for column , ℎ𝑤=7 to 13 mm are used. The weir length
determines the down comer area. A weir length of 60 to 80% of tower diameter is normally
used with segmental down comers.

CALMING ZONE:
Two blank areas are called calming zone. Two types of zone inlet calming helps in reducing
excessive weeping and out let calming zone allows dis engagement of vapor before liquid enter
down comer area.

50 to 100 mm suggested
Here some pic which clear concept of tray design
DESIGN PROBLRM:
Design a continuous distillation column (plate) to recover acetone from a 50-50 mole % acetone-
water mixture available at 30°C. The feed stream flow rate is 25,000 kg/h. The top product should
contain at least 95 mole% acetone and the bottom product should contain <1 % acetone by mole.
Consider reboiler as equivalent to one stage. This column is operated at atmospheric pressure (top
tray). Column efficiency of 60% and pressure drop per plate of 1.25 kPa may be assumed. You can
take the minimum liquid flow as 70% of the maximum rate both above and below the feed plate.
The vapor liquid equilibrium (VLE) data for the acetone-water system at atmospheric pressure is
provided in Table

DATA:
Latent heat of water= 41,360 J/mol;
 latent heat of acetone= 28,410 J/mol

Specific heat of water=75.3 J/mol°C

Specific heat of acetone 128 J/mol°C

𝒙 0.0 0.0 0.1 0.1 0.2 0.2 0.3 0.3 0.4 0.4 0.5 0.5 0.6 0.6 0.7 0.7 0.8 0.8 0.9 .95
5 0 5 0 5 0 5 0 5 0 5 0 5 0 5 0 5
𝒚 0.0 0.6 0.7 0.7 0.7 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.9 0.9 0.9
38 30 71 91 03 12 20 26 37 38 45 53 61 71 81 95 11 33 62
1 1 6 6 4 4 1 9 6 7 5 2 5 2 7 8 5 7
BP 10 74. 68. 65. 0.6 62. 61. 61. 60. 60. 59. 59. 59. 58. 58. 57. 57. 57. 56. 56.
, 0 8 53 26 3.5 6 87 26 75 35 95 54 12 71 29 9 49 08 68 3
°C 9

X= Mole fraction of acetone in liquid;

Y= Mole fraction of acetone in vapor; BP: Bubble point

STEP 1: MASS BALANCE AND DETERMINATION OF NUMBER OF THEORITICAL PLATES

FEED AND PRODUCT COMPOSITION
Component Feed mole fraction Top product mole Bottom product
fraction mole fraction
Acetone 0.50 0.95 0.01

Water 0.50 0.05 0.99

Bubble point of feed (from the data shown in table) = 59.95°C

Latent heat of the feed = 28,410×0.5 + 41,360×(1 - 0.5) = 34,885 J/mol
Specific heat of the feed = (128×0.5) + 75.3× (1 - 0.5) = 101.75 J/mol °C

Heat required to vaporize 1 mole of the given feed = (59.95 - 30) ×101.75 + 34,885=37933 J

𝑞 = Heat required to vaporize 1 mole of the given feed = 377933

Latent heat of the feed 34885

Slope of the q-line= 𝑞 /𝑞−1 = 1.09/ 1.09−1 = 12.44

XD/ Rmin + 1= 0.57 , Rmin= 0.67 , Xd= 0.95

Here, reflux ratio,

R=2.5×Rmin =2.5×0.67= 1.675 is taken for this design.
Average molecular wt. of feed= 0.5×58 + 0.5×18=38
Molar feed flow (𝐹) rate=25,000/38=657.9 kmol/h
Acetone balance: = 𝐷 × 0.95 = 657.9 × 0.5⇒𝐷 = 346.2 kmol/h
Vapor flow (𝑉) rate above feed plate, 𝑉 = 𝐷 1 + 𝑅 = 346.2 1 + 1.675 = 926.2
kmol/h

(Assuming constant molar overflow)

Top section liquid flow rate, 𝐿 = 𝑉 − 𝐷 = 580 kmol/h
Bottom product: 𝐵 = 𝐹 − 𝐷 = 657.9 − 346.2 = 311.7 kmol/h
Mass balance below feed plate: 𝐿′ = 𝑉′ + 𝐵
Slope of the bottom section operating line (Figure 7.8): 𝐿′ 𝑉 ′ = 1.32
𝐿′= Liquid flow rate below feed plate = 1285.7 kmol/h
𝑉′= Vapor flow rate below feed plate = 974 kmol/h
The construction of operating lines and number of theoretical stages are shown in
this figure
Total number of tray
= 6 (above feed) +3 (below feed) =9
Total number of real stages
= 9−1 0.6 ≈ 14 (60% column efficiency; reboiler was considered as equivalent to
one theoretical tray)

STEP 2: ESTIMATE THE PHYSICAL PROPERTIES

Column top pressure= 101325 Pa (1 atm)
Column pressure drop=1.25×103×14=16800 kPa
Pressure drop of 1.25kPa per tray is specified

Top section: Bottom section:

Column top pressure= 101325 Pa Column bottom pressure=101325
(1.0147 bar) and temperature= 56.3 +16800 = 118825 Pa (=1.19 bar)
°C

𝜌𝑣 = 𝑃𝑀 𝑅𝑇 = 101325 ×56.5 Boiling point of water at 118825 Pa

329.3×8.314×103 = 2.08 kg/m3 (1.19 bar)= 105 °C (bottom contains
99 mole % water)
𝜌𝑙 =744 kg/m3 (density of the From the steam table at 118825 Pa
mixture) and 105 °C: 𝜌𝑣 = 0.693; 𝜌𝑙 = 955
(water density= 985 and acetone kg/m3
density= 735 kg/m3 at 56.3 °C) Average molecular weight of
vapor: M=40.58
Average molecular weight of vapor: Average molecular weight of
M=56.5 liquid: M=18.4
Average molecular weight of liquid:
M=56
Surface tension, O = 58*10*3
𝜍 =20×10-3 N/m

STEP 4: COLUMN DIAMETER

1st trial is started with the following considerations:
Design is performed for 80% flooding at maximum gas flow rate.
Total downcomer top and bottom seal area is 10% of the net area.

Top section: Bottom section:

Flow parameter (𝐹𝐿𝐺) based on 𝐹𝐿𝐺=𝐿′/𝑉′( 𝜌𝑣/𝜌𝑙)* 0.5
mass flow rate, =1285.7×18.4/974×40.58
(0.693/955)* 0.5=0.016
𝐿𝑉 (𝜌𝑣/𝜌𝑙
)*0.5=580×56/926.2×56.5 𝐶𝑠𝑏𝑓=0.11 m/s
(2.08/744 )*0.5=0.033
𝑈𝑛𝑓=𝐶𝑠𝑏𝑓 (𝜍/20)* 0.2(
Capacity parameter (𝐶𝑠𝑏𝑓) =0.12 𝜌𝑙−𝜌𝑣𝜌𝑣)* 0.5=0.11× (58/20)*
m/s 0.2 (955−0.693/0.693)* 0.5
=5.05 m/s
Gas velocity through the net area
at flooding: 𝑈𝑛=0.8×5.05=4.04 m/s

𝑈𝑛𝑓=𝐶𝑠𝑏𝑓( 𝜍/20)* 0.2 𝑄𝑚𝑎𝑥=𝑉×𝑀/𝜌𝑣=974×40.58/0.

(𝜌𝑙−𝜌𝑣𝜌𝑣)* 0.5 693
=0.12× (20/20 )*0.2 = 57034.5 m3/h
(744−2.08/2.08)* 0.5 =15.84 m3/s
=2.26 m/s

[𝜍 = liquid surface tension, mN/m]

The linear design gas velocity (𝑈𝑛)
based on net area (80% flooding):

𝑈𝑛=0.8×2.26=1.8 m/s

The maximum volumetric vapor

flow rate (𝑄𝑚𝑎𝑥):

𝑄𝑚𝑎𝑥=𝑉×𝑀/𝜌𝑣=926.2×56.5/2.
08
=25158.8 m3/h
=6.98 m3/s

Net area required: 𝑄𝑚𝑎𝑥/𝑈𝑛=15.84/4.04=3.92 m2

𝑄𝑚𝑎𝑥/𝑈𝑛=6.98/1.8
=3.88 m2
Totals tower cross-section area: =3.92/0.9=4.36 m2
3.88/0.9=4.31 m2

(Total downcomer top and bottom Colum (tower) diameter:

seal area is 10% of the net area) (4.36/0.785)*=2.36 m

Colum (tower) diameter:

(4.31/0.785)*0.5=2.34 m

Step #5: Selection of liquid-flow arrangement

Liquid volumetric flow rate in the top section =580×56/3600×744
≈0.012m3/s

Liquid volumetric flow rate in the top section

=1285.7×18.4/3600×955 ≈0.007m3/s
Therefore, single pass cross-flow sieve plate is chosen for this service

STEP 6: PROVISIONAL PLATE DESIGN:

Column (tower) diameter (ID): 𝐷𝑇≈2.4 m
Column cross-section area: 𝐴𝑇=0.785×𝐷𝑇2=4.52 m2
Downcomer area: 𝐴𝐷=0.1𝐴𝑇= 0.452 m2
Net area: 𝐴𝑁=𝐴𝑇−𝐴𝐷= 4.068 m2
Weir Length (𝑙𝑊) = 0.73×𝐷𝑇 = 1.752 m
Weir height, ℎ𝑤= 40 mm is considered.
Active area:𝐴𝐴=𝐴𝑇−2×𝐴𝐷=3.616 m2

*For the first trial, consider hole diameter: 𝑑ℎ=12 mm (12inch). The
plate thickness=hole diameter is selected for the first trial.
STEP 6 : CHECK WEEPING
Top section Bottom section
Maximum liquid flow rate 𝑚𝑚𝑎𝑥=1285.7×18.4/3600
(𝑚𝑚𝑎𝑥) =6.571 kg/s
= 580×56/3600=9.02 kg/s

Minimum liquid flow rate 𝑚𝑚𝑖𝑛=0.7×6.571

(𝑚𝑚𝑖𝑛) (70% of 𝑚𝑚𝑎𝑥) =4.6 kg/s
=0.7×9.02=6.32 kg/s

Maximum weir crest, ℎ𝑤𝑐=750( 6.571/1.752

ℎ𝑤𝑐=750 (𝐿𝑤𝑐/𝐿𝑊𝜌𝑙)* 2/3 ×955)* 2/3 =18.7 mm liquid
=750( 9.02/1.752 ×744)* 23 height
=27.2 mm liquid height
Minimum weir crest, ℎ𝑤𝑐=750 (4.6/1.752 ×955)
ℎ𝑤𝑐=750 (𝐿𝑤𝑐/𝐿𝑊𝜌𝑙)* 2/3 *2/3 =14.7 mm liquid height
=750 (6.32/1.752 ×744)*
2/3 𝐾2= 30.2at ℎ𝑤𝑐+ℎ𝑤=54.7
=21.5 mm liquid height 𝑈min at the weep point:
The constant (𝐾2) of weep- 𝑈min=30.2−0.9(25.4−12)/(0.
point correlation= 30.3 693)*1/2=21.8 m/s
at ℎ𝑤𝑐+ℎ𝑤=40+21.5=61.5
mm

The minimum vapor velocity

(𝑈min) at the weep point:

𝑈min=𝐾2−0.9(25.4−𝑑ℎ)𝜌𝑣1
/2=30.3−0.9(25.4−12)/(2.0
8)1/2
=12.6 m/s
Actual minimum vapor
velocity at minimum vapor
flow rate:
=Actual vapor flow rate/𝐴𝐻 =0.7×15.84/0.489
=70 % of =22.7 m/s
𝑄𝑚𝑎𝑥/𝐴𝐻=0.7×6.98/0.489
=10 m/s

STEP 8: PLATE PRESSURE DROP

Top section Bottom section
Maximum vapor velocity: 𝑈𝑚𝑎𝑥=𝑄𝑚𝑎𝑥/𝐴𝐻=15.84/0.489
𝑈𝑚𝑎𝑥=𝑄𝑚𝑎𝑥/𝐴𝐻=6.98/0.489 =32.4 m/s
=14.3 m/s
ℎ𝑑=51 (32.4/0.88)* 2
Maximum dry plate pressure (0.693/955)= 50.2 mm liquid
drop:
ℎ𝑑=51 (𝑈𝑚𝑎𝑥/𝐶0)* 2 ℎ𝑟=12.5×103/𝜌𝑙=12.5×103/95
𝜌𝑣/𝜌𝑙=51( 14.3/0.88)* 2 5
(2.08/744) =13 mm liquid
= 37.5 mm liquid
The orifice coefficient, 𝐶0=0.88 ℎ𝑡= 50.2 + (40+18.7)+13≈122
at 𝐴𝐻/𝐴𝑃=15% and plate mm liquid
thickness/hole diameter
=1
Residual head:
ℎ𝑟=12.5×103/𝜌𝑙=12.5×103/74
4=16.8 mm liquid

Total plate pressure drop:

ℎ𝑡=ℎ𝑑+ ℎ𝑤𝑐+ℎ𝑤 +ℎ𝑟= 37.5 +
(40+27.2)+16.8≈122 mm liquid

STEP 9: DOWNCOMER BACKUP LIQUID AND RESIDENCE TIME

Downcomer back:
ℎ𝑏= ℎ𝑤𝑐+ℎ𝑤 +ℎ𝑡+ℎ𝑑𝑐
Head loss in downcomer:
ℎ𝑑𝑐=166 𝐿𝑤𝑑𝜌𝑙𝐴𝑚 2
Downcomer liquid flow rate (𝐿𝑤𝑑) =maximum liquid flow rate is
taken
𝐴𝑚 is smaller of 𝐴𝑎𝑝 and 𝐴𝐷.
𝐴𝑎𝑝=ℎ𝑎𝑝𝑙𝑤=30×10−3×1.752=0.0525 m2 (typically
ℎ𝑎𝑝=ℎ𝑤−10)
Here, 𝐴𝑎𝑝<𝐴𝐷=0.452 m2
Top section Bottom section
ℎ𝑑𝑐=166( 9.02/744×0.0525)* ℎ𝑑𝑐=166 (6.57/1955×0.0525)
2=8.8 mm *2=2.9 mm
ℎ𝑏= 27.2+40 +122+8.8≈198 ℎ𝑏= 18.7+40 +122+2.9≈184
mm mm
Downcomer residence time: 𝑡𝑑𝑟𝑡=0.452×(184×10−3)×955
𝑡𝑑𝑟𝑡=𝐴𝐷ℎ𝑏𝑐𝜌𝑙/𝐿𝑤𝑑=(0.452× /6.571≈ 12 s >3 s.
184×10−3 ×955/6.571)≈ 12 s
>3 s.
ℎ𝑏𝑐=clear liquid back up
(ℎ𝑏𝑐≈ℎ𝑏can be approximated)

STEP 10: CALMING ZONE AND HOLE PITCH

Perforated area (𝐴 𝑃 ): =AA - ACZ – AES
Where,
𝐴 𝐶𝑍 = calming zone area
𝐴 𝐸𝑆 = area occupied by edge strip
𝑙 𝑊 /𝐷 𝑇 =0.73;
now, 𝜃 𝑐 = 95°
Angle subtended by the chord (edge plate), 𝛼 = 180°-95° = 85°

The unperforated edge strip (edge plate) mean length from the
geometry:

𝑙 𝐸𝑆 =(𝐷 𝑇 -50×10-3)×𝛼 ×𝜋 180 =(2.4-50×10-3)×85×𝜋 180

=3.49 m
𝐴 𝐸𝑆 = 50×10-3×𝑙 𝑀𝑆 =0.175 m2
Use 50 mm wide calming zones. The approximate mean length
of zones:
𝑙 𝐶𝑍 =Weir length (𝑙 𝑊) + Width of unperfortaed edge strip
=1.752+50×10-3=1.802 m
𝐴 𝐶𝑍 = 2(50×10-3×𝑙 𝐶𝑍 )= 0.18 m2
Therefore, perforation area per tray (𝐴 𝑃 ) = 𝐴 𝐴 − 𝐴 𝐶𝑍 − 𝐴 𝐸𝑆
=3.616- 0.18-0.175= 3.26 m2

Take total hole area 𝐴 𝐻 = 0.15𝐴 𝐴 = 0.489 m2

𝐴 𝐻 = 0.785 ×𝑑 ℎ 2 ×𝑛 ℎ = 0.489 m2 [hole diameter 12 mm]

Number of holes (𝑛 ℎ) = 4326
𝐴 𝐻 /𝐴 𝑃 = 0.15. For equilateral triangular pitch: 𝐴 𝐻 /𝐴 𝑃 =
0.907 (𝑑 ℎ/ 𝐼 𝑃)* 2

This corresponds to hole-pitch to hole diameter ratio of (𝐼 𝑃 /𝑑 ℎ

) = 2.46. This is very close to the normal range of 2.5 to 4.0
times of hole diameter.
The estimated hole pitch (𝐼 𝑃 )=is 29.5 mm

STEP 11 and 12: ENTRAINMENT CHECKING:

Top section Bottom section
Actual vapor velocity (𝑈𝑣) 𝑈𝑣=𝑄𝑚𝑎𝑥/𝐴𝑁=15.84/4.068
based on net area (𝐴𝑁) selected =3.9 m/s
provisionally:
%flooding=𝑈𝑣/𝑈𝑛𝑓×100
𝑈𝑣=𝑄𝑚𝑎𝑥/𝐴𝑁=6.98/4.068=1. =3.9/5.05×100=77%
7 m/s
Ψ=0.18 at 𝐹𝐿𝐺=0.016 and
%flooding=𝑈𝑣/𝑈𝑛𝑓×100=1.7/ actual flooding velocity of 77 %
2.26×100 𝐸𝑎=0.53
=76 %

The fractional entrainment,

Ψ=0.09 at 𝐹𝐿𝐺=𝐿/𝑉(
𝜌𝑣/𝜌𝑙)*0.5=0.033 and actual
flooding velocity of 76 %

Effect of Ψ on Murphree plate

efficiency can be estimated from
EQ

𝐸𝑎=𝐸𝑚𝑣1+Ψ𝐸𝑚𝑣1−Ψ=0.57
𝐸𝑚𝑣=0.6 (Murphree vapor
efficiency 60%)
E𝑎=Murphree vapor efficiency,
corrected for liquid entrainment

The actual flooding is below the design flooding value of 80%.

Usually, Ψ<0.1 is desirable. However, the optimum design value
may be above this.

Assumptions/ design considerations:

Lean water-NH3 system follows Henry’s law and the corresponding
equilibrium relation: 𝑦∗=0.85𝑥 @30°C
Isothermal gas absorption at room temperature (~30°C)
Optimum adsorption factor (𝐴)= 1.2 to 2
Overall column efficiency=70%
Pressure drop per plate= 1 kPa
Minimum liquid loading=70% of expected maximum loading