Page : 1 of 103

Rev: 04
KLM Technology
Group
Rev 1 Feb 2007
Practical Engineering
Guidelines for Processing Plant
Engineering Solutions Rev 2 April 2008
Solutions Rev 3 Feb 2011
Rev 4 June 2013
www.klmtechgroup.com

Co Author:
KLM Technology Group Kolmetz Handbook Rev 1 Chew Yin Hoon
P. O. Box 281 Rev 2 Ai Li Ling
Bandar Johor Bahru, of Process Equipment Design Rev 3 Aprilia Jaya
80000 Johor Bahru, Johor, Rev 4 Mochamad Adha Firdaus
West Malaysia
Distillation Column
Selection, Sizing Author / Editor

and Troubleshooting Karl Kolmetz

(ENGINEERING DESIGN GUIDELINES)

TABLE OF CONTENTS

INTRODUCTION

Scope 6

Distillation 7

Distillation History 7

Types of Distillation Processes 9

Mode of Operation 10

Column Internals 11

Types of Distillation Column 15

A. Tray Column 15

A.1 Tray Hydraulic 18

B. Packed Column 21

B.1 Packed Hydraulic 23

This design guideline are believed to be as accurate as possible, but are very general not for specific design cases. They
were designed for engineers to do preliminary designs and process specification sheets. The final design must always be
guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up
front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers
or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 2 of 103
Kolmetz Handbook
KLM Technology of Process Equipment Design Rev: 04
Group
Practical Engineering Distillation Column
Guidelines for Processing
Plant Solutions
Selection, Sizing
and Troubleshooting June 2013
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINES)

General Design Consideration 26

The Selection of Column Internals 28

DEFINITIONS 34

NOMENCLATURE 36

THEORY

(A) Vapor-Liquid Equilibrium (VLE) 38

(I) Ideal Behavior in Both Phases 38

(II) Liquid Phase Non-Idealities 39

(a) Local composition equations 40

(b) Activity coefficient estimation methods 40

(III) High-Pressure Systems 41

(a) Vapor fugacity coefficient, liquid activity coefficient 41

(b) Vapor and liquid fugacity coefficients 42

(B) Phase Distribution 42

(I) Incompressible liquid 43

(II) Negligible Poynting correction 43

(III) Vapor obeying the ideal gas law 43

This design guideline are believed to be as accurate as possible, but are very general not for specific design cases. They
were designed for engineers to do preliminary designs and process specification sheets. The final design must always be
guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up
front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers
or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 3 of 103
Kolmetz Handbook
KLM Technology of Process Equipment Design Rev: 04
Group
Practical Engineering Distillation Column
Guidelines for Processing
Plant Solutions
Selection, Sizing
and Troubleshooting June 2013
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINES)

(IV) Ideal liquid solution 44

(V) Other methods to determine K-values 44

(C) Distillation Calculations 45

(I) Product specifications 45

(II) Column operating pressure 45

(III) Operating Reflux Ratio and Number of Stages 47

(a) Minimum reflux ratio 48

(b) Minimum stages 49

(c) Number of actual theoretical stages 51

(IV) Tower Diameter 57

(a) Trayed columns 57

(b) Packed columns 60

(V) Efficiency Tower 65

(a) Trayed Efficiency 65

(b) HETP 68

(D) Control Schemes 69

(I) Pressure Control 69

(II) Temperature Control 72

(III) Flow Control 74

This design guideline are believed to be as accurate as possible, but are very general not for specific design cases. They
were designed for engineers to do preliminary designs and process specification sheets. The final design must always be
guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up
front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers
or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 4 of 103
Kolmetz Handbook
KLM Technology of Process Equipment Design Rev: 04
Group
Practical Engineering Distillation Column
Guidelines for Processing
Plant Solutions
Selection, Sizing
and Troubleshooting June 2013
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINES)

(IV) Level Control 74

(V) Reflux Control 75

(V) Boilup Control 75

APPLICATION

Example 1: Determination of Theoretical Stages and Reflux Ratio 77

Example 2: Trayed Column Diameter Determination 81

Example 3: Packed Column Diameter Determination 82

Example 4: Trayed Column Efficiency Determination 84

Example 5: HETP Determination 86

REFERENCES 88

LIST OF TABLE

Table 1: Pressure drop in difference services 32

Table 2: Common temperature differences for difference types of medium

in condenser and Reboiler. 45

Table 3: Packing Factors (Fp) 64

Table 4: Constant n for HETP Correlation 70

This design guideline are believed to be as accurate as possible, but are very general not for specific design cases. They
were designed for engineers to do preliminary designs and process specification sheets. The final design must always be
guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up
front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers
or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 5 of 103
Kolmetz Handbook
KLM Technology of Process Equipment Design Rev: 04
Group
Practical Engineering Distillation Column
Guidelines for Processing
Plant Solutions
Selection, Sizing
and Troubleshooting June 2013
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINES)

LIST OF FIGURE

Figure 1: Batch Still Distillation Process 8

Figure 2: Still Distillation in Series 8

Figure 3: Extractive Distillation Column 9

Figure 4: Catalyst Distillation Column 10

Figure 5: Schematic Diagram of Distillation Column/ Fractionator. 10

Figure 6: Rectifying Stages 12

Figure 7: Stripping Stages 13

Figure 8: Total Condenser 14

Figure 9: Partial Condenser 14

Figure 10: Work of Tray 15

Figure 11: Types of Tray Distillation Column (a) Bubble Cap Tray, )b) Sieve Tray
(c) Valve Tray 16

Figure 12: Kind of Baffle Tray; (a) Shed Deck Tray, (b) Side to Side Tray, (c) Disk
and Donuts Tray 17

Figure 13: Operating Region of Tray 18

Figure 14: Type of Downcomer 21

Figure 15: Types of Packed Column; (a) Random Packed Column, (b) Grid
Packed Column, (c) Structured Packed Column 22

Figure 16: Operating Area of Packed Column 23

Figure 17: Stacked Packing to Support Random Packing 32

This design guideline are believed to be as accurate as possible, but are very general not for specific design cases. They
were designed for engineers to do preliminary designs and process specification sheets. The final design must always be
guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up
front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers
or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 6 of 103
Kolmetz Handbook
KLM Technology of Process Equipment Design Rev: 04
Group
Practical Engineering Distillation Column
Guidelines for Processing
Plant Solutions
Selection, Sizing
and Troubleshooting June 2013
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINES)

Figure 18: Orifice Type Distributor 33

Figure 19: Liquid Redistributors 33

Figure 20: Relationship between Reflux Ratio and Number of Stages 45

Figure 21: Application of McCabe-Thiele to VLE Diagram 52

Figure 22: Constructing of Operating Line for Stripping Section 53

Figure 23: Example of a Seven Stage Distillation 54

Figure 24: Erbar-Maddox Correlation of Stage Vs Reflux 56

Figure 25: Internal of Bubble-caps Trays Column 56

Figure 26: Souders-Brown Correlation for Approximation Tower Sizing 59

Figure 27: Valve Tray Column Diameter 61

Figure 28: Packed Column Pressure Drop Correlation 62

Figure 29: Internal of Packing Column 63

Figure 30: O’Connel Column Efficiency 66

Figure 31: Control pressure for distillation towers 69

Figure 31.a : Control pressure for distillation towers (2) 70

Figure 32: Control pressure for distillation towers (3) 71

Figure 33: Control pressure for distillation towers (4) 71

Figure 34: Control pressure for distillation towers (5) 72

Figure 35: Control temperature for distillation towers 73

This design guideline are believed to be as accurate as possible, but are very general not for specific design cases. They
were designed for engineers to do preliminary designs and process specification sheets. The final design must always be
guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up
front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers
or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 7 of 103
Kolmetz Handbook
KLM Technology of Process Equipment Design Rev: 04
Group
Practical Engineering Distillation Column
Guidelines for Processing
Plant Solutions
Selection, Sizing
and Troubleshooting June 2013
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINES)

Figure 36: Control temperature for distillation towers (2) 73

Figure 37: Control level for distillation towers 74

Figure 38: Control level for distillation towers (2) 75

Figure 39: Control boilup for distillation towers 76

This design guideline are believed to be as accurate as possible, but are very general not for specific design cases. They
were designed for engineers to do preliminary designs and process specification sheets. The final design must always be
guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up
front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers
or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 8 of 103
Kolmetz Handbook
KLM Technology of Process Equipment Design Rev: 04
Group
Practical Engineering Distillation Column
Guidelines for Processing
Plant Solutions
Selection, Sizing
and Troubleshooting June 2013
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINES)

INTRODUCTION

Scope

This design guideline covers the basic elements in designing a typical distillation column
system, which includes column internals selection and sizing.

In designing a distillation column, the thermodynamics of the vapor and liquid phases
must be understood. The vapor-liquid equilibrium (VLE) determines the minimum number
of stages required to achieve the degree of separation needed. The minimum reflux ratio
also depends on the VLE data of the mixture.

A few equations that are commonly used in the industry are illustrated in this guideline to
estimate the minimum number of stages and the minimum reflux ratio of a column based
on the VLE data, such as the Fenske-Underwood equation. Some design heuristics are
also highlighted. These rules are based on design experiences and take into account both
the safety and economical factors.

The selection of column internals is very critical in distillation column design. There is a
wide variety of trays and packings in the market. Each design has its strengths and
weaknesses. However, the quotations from vendors are sometimes contradictory and
confusing. This could lead to a wrong choice of column internal. Therefore, some general
considerations are depicted to aid engineers in making the right choice of column
internals. In general select trays for high pressure and packings for low pressure.

A distillation column is sized by determining the diameter of the tower. An initial

estimation of the tower diameter can be done based on the vapor and liquid loadings in
the column.

Included in this guideline is an example of the data sheet used in the industry and a
calculation spreadsheet for the engineering design.

This design guideline are believed to be as accurate as possible, but are very general not for specific design cases. They
were designed for engineers to do preliminary designs and process specification sheets. The final design must always be
guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up
front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers
or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 9 of 103
Kolmetz Handbook
KLM Technology of Process Equipment Design Rev: 04
Group
Practical Engineering Distillation Column
Guidelines for Processing
Plant Solutions
Selection, Sizing
and Troubleshooting June 2013
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINES)

Distillation

Distillation is by far the most important separation process in the petroleum and chemical
industries. It is the separation of key components in a mixture by the difference in their
relative volatility, or boiling points. It is also known as fractional distillation or fractionation.

In most cases, distillation is the most economical separating method for liquid mixtures.
However, it can be energy intensive. Distillation can consume more than 50% of a plant’s
operating energy cost. There are alternatives to distillation process such as solvent
extraction, membrane separation or adsorption process. On the other hand, these
processes often have higher investment costs. Therefore, distillation remains the main
choice in the industry, especially in large-scale applications.

Distillation History

The history of distillation dated back to centuries ago. Forbes has chronicled the full
history of distillation in 19481. Reputedly, it was the Chinese who discovered it during the
middle of the Chou dynasty. It was later introduced to India, Arabia, Britain and the rest of
the world.

Early distillation consisted of simple batch stills to produce ethanol. Crude ethanol was
placed in a still and heated, and the vapor drawn from the still was condensed for
consumption. Lamp oil was later produced using the same method, with crude oil heated
in batch stills.

The next progression in the history of distillation was to continually feed the still and
recover the light product. Further advancements include placing the stills in series and
interchanging the vapor and liquid from each still to improve recovery. This was the first
type of counter-current distillation column that we have today.

This design guideline are believed to be as accurate as possible, but are very general not for specific design cases. They
were designed for engineers to do preliminary designs and process specification sheets. The final design must always be
guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up
front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers
or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 10 of 103
Kolmetz Handbook
KLM Technology of Process Equipment Design Rev: 04
Group
Practical Engineering Distillation Column
Guidelines for Processing
Plant Solutions
Selection, Sizing
and Troubleshooting June 2013
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINES)

Furnace Condenser

Figure 1: Batch Still Distillation Process

This design guideline are believed to be as accurate as possible, but are very general not for specific design cases. They
were designed for engineers to do preliminary designs and process specification sheets. The final design must always be
guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up
front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers
or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 11 of 103
Kolmetz Handbook
KLM Technology of Process Equipment Design Rev: 04
Group
Practical Engineering Distillation Column
Guidelines for Processing
Plant Solutions
Selection, Sizing
and Troubleshooting June 2013
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINES)

CONDENSATE
63% PENTANE VAPORS VAPORS
37% HEXANE 49% PENTANE 35% PENTANE
51% HEXANE 65% HEXANE

STILL 1 STILL 2 STILL 3

126oF 135oF 143oF

FEED
50% PENTANE
50% HEXANE LIQUID LIQUID Heat
37% PENTANE 25% PENTANE
63% HEXANE 75% HEXANE LIQUID
15% PENTANE
85% HEXANE

Figure 2: Still Distillation in Series

Types of Distillation Processes

There are many types of distillation processes. Each type has its own characteristics and
is designed to perform specific types of separations. These variations appear due to
difficulty in separation when the physical properties of the components in a mixture are
very close to one another, such as an azeotropic mixture.

One type of variation of the distillation processes is extractive distillation. In this type of
process, an external solvent is added to the system to increase the separation. The
external solvent changes the relative volatility between two ‘close’ components by
extracting one of the components, forming a ternary mixture with different properties. The
solvent is recycled into the system after the extracted component is separated from it.

This design guideline are believed to be as accurate as possible, but are very general not for specific design cases. They
were designed for engineers to do preliminary designs and process specification sheets. The final design must always be
guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up
front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers
or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 12 of 103
Kolmetz Handbook
KLM Technology of Process Equipment Design Rev: 04
Group
Practical Engineering Distillation Column
Guidelines for Processing
Plant Solutions
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and Troubleshooting June 2013
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINES)

Reflux
Bed 1
Bed 2
Lean Solvent

Bed 3

Bed 4

Feed

Figure 3: Extractive Distillation Column

A distillation column may also have a catalyst bed and reaction occurring in it. This type of
column is called a reactive distillation column. The targeted component reacts when it is
in contact with the catalyst, thereby separated from the rest of the components in the
mixture.

This design guideline are believed to be as accurate as possible, but are very general not for specific design cases. They
were designed for engineers to do preliminary designs and process specification sheets. The final design must always be
guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up
front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers
or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 13 of 103
Kolmetz Handbook
KLM Technology of Process Equipment Design Rev: 04
Group
Practical Engineering Distillation Column
Guidelines for Processing
Plant Solutions
Selection, Sizing
and Troubleshooting June 2013
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINES)

Hydrogen
Vent

Reflux + Heat of Rx
Hydrogen
Net
Catalyst Overhead
Tower
Feed Zone

Net
Bottoms

Figure 4: Catalyst Distillation Column

This design guideline are believed to be as accurate as possible, but are very general not for specific design cases. They
were designed for engineers to do preliminary designs and process specification sheets. The final design must always be
guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up
front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers
or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 14 of 103
Kolmetz Handbook
KLM Technology of Process Equipment Design Rev: 04
Group
Practical Engineering Distillation Column
Guidelines for Processing
Plant Solutions
Selection, Sizing
and Troubleshooting June 2013
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINES)

Mode of Operation

Distillation towers can be classified into two main categories, based on their mode of
operation. The two classes are batch distillation and continuous distillation.

In batch distillation, the feed to the column is introduced batch-wise. The column is first
charged with a ‘batch’ and then the distillation process is carried out. When the desired
task is achieved, the next batch of feed is introduced. Batch distillation is usually preferred
in the pharmaceutical industries and for the production of seasonal products.

On the other hand, continuous distillation handles a continuous feed stream. No

interruption occurs during the operation of a continuous distillation column unless there is
a problem with the column or surrounding unit operations. Continuous columns are
capable of handling high throughputs. Besides, additional variations can be utilized in a
continuous distillation column, such as multiple feed points and multiple product drawing
points. Therefore, continuous columns are the more common of the two modes,
especially in the petroleum and chemical industries.

Column Internals

Column internals are installed in distillation columns to provide better mass and heat
transfers between the liquid and vapor phases in the column. These include trays,
packings, distributors and redistributors, baffles and etc. They promote an intimate
contact between both phases. The type of internals selected would determine the height
and diameter of a column for a specified duty because different designs have various
capacities and efficiencies. The two main types of column internals discussed in this
guideline are trays and packing.

There are many types of trays or plates, such as sieve, bubble-cap and valve trays.
Packing, on the other hand, can be categorized into random and structured packing. In
random packing, rings and saddles are dumped into the column randomly while
structured packing is stacked in a regular pattern in the column.

This design guideline are believed to be as accurate as possible, but are very general not for specific design cases. They
were designed for engineers to do preliminary designs and process specification sheets. The final design must always be
guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up
front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers
or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 15 of 103
Kolmetz Handbook
KLM Technology of Process Equipment Design Rev: 04
Group
Practical Engineering Distillation Column
Guidelines for Processing
Plant Solutions
Selection, Sizing
and Troubleshooting June 2013
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINES)

Condenser
Overhead
Receiver
Overhead
Product

R
Feed

Reboiler
Bottom
Product

Figure 5: Schematic Diagram of Distillation Column/ Fractionator.

Figure 5 shows a schematic diagram of an example distillation column or fractionator. The

feed enters the column as liquid, vapor or a mixture of vapor-liquid. The vapor phase that
travels up the column is in contact with the liquid phase that travels down. Column
distillation is divided two stages, there are rectifying stages and striping stages.

This design guideline are believed to be as accurate as possible, but are very general not for specific design cases. They
were designed for engineers to do preliminary designs and process specification sheets. The final design must always be
guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up
front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers
or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 16 of 103
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Group
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(ENGINEERING DESIGN GUIDELINES)

(A) Rectifying Stages

The process above the feed tray is known as rectification (where the vapor phase is
continually enriched in the light components which will finally make up the overhead
product). A liquid recycle condenses the less volatile components from rising vapor. To
generate the liquid recycle, cooling is applied to condense a portion of the overhead
vapor its name reflux.

(B) Stripping Stages

The process below the feed tray is known as stripping (as the heavier components are
being stripped off and concentrated in the liquid phase to form the bottom product). At the
top of the column, vapor enters the condenser where heat is removed. Some liquid is
returned to the column as reflux to limit the loss of heavy components overhead.

At each separation stage (each tray or a theoretical stage in the packing), the vapor
enters from the stage below at a higher temperature while the liquid stream enters from
the stage above at a lower temperature. Heat and mass transfer occur such that the
exiting streams (bubble point liquid and dew point vapor at the same temperature and
pressure) are in equilibrium with each other.

(C) Condenser

The condenser above the column can be either a total or partial condenser. In a total
condenser (Figure 8), all vapors leaving the top of the column is condensed to liquid so
that the reflux stream and overhead product have the same composition.

In a partial condenser (Figure 9), only a portion of the vapor entering the condenser is
condensed to liquid. In most cases, the condensed liquid is refluxed into the column and
the overhead product drawn is in the vapor form. On the other hand, there are some
cases where only part of the condensed liquid is refluxed. In these cases, there will be
two overhead products, one a liquid with the same composition as the reflux stream while
the other is a vapor product that is in equilibrium with the liquid reflux.

This design guideline are believed to be as accurate as possible, but are very general not for specific design cases. They
were designed for engineers to do preliminary designs and process specification sheets. The final design must always be
guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up
front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers
or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 17 of 103
Kolmetz Handbook
KLM Technology of Process Equipment Design Rev: 04
Group
Practical Engineering Distillation Column
Guidelines for Processing
Plant Solutions
Selection, Sizing
and Troubleshooting June 2013
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINES)

Vent

Condensate
Liquid

Figure 8: Total Condenser

Vent

This design guideline are believed to be as accurate as possible, but are very general not for specific design cases. They
were designed for engineers to do preliminary designs and process specification sheets. The final design must always be
guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up
front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers
or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyrightVaporremainsproduct

with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 18 of 103
Kolmetz Handbook
KLM Technology of Process Equipment Design Rev: 04
Group
Practical Engineering Distillation Column
Guidelines for Processing
Plant Solutions
Selection, Sizing
and Troubleshooting June 2013
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINES)

Figure 9: Partial Condenser

This design guideline are believed to be as accurate as possible, but are very general not for specific design cases. They
were designed for engineers to do preliminary designs and process specification sheets. The final design must always be
guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up
front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers
or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 19 of 103
Kolmetz Handbook
KLM Technology of Process Equipment Design Rev: 04
Group
Practical Engineering Distillation Column
Guidelines for Processing
Plant Solutions
Selection, Sizing
and Troubleshooting June 2013
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINES)

DEFINITIONS

Azeotrope- Is a mixture of two or more pure compounds (chemicals) in such a ratio that
its composition cannot be changed by simple distillation. This is because when an
azeotrope is boiled, the resulting vapor has the same ratio of constituents as the original
mixture of liquids.

Bottoms – The stream of liquid product collected from the reboiler at the bottom of a
distillation tower.

Bubble point – The temperature at constant pressure (or the pressure at constant
temperature) at which the first vapor bubble forms when a liquid is heated (or
decompressed).

Condenser- Is a heat exchanger which condenses a substance from its gaseous to its
liquid state.

Dew point – The temperature at constant pressure (or the pressure at constant
temperature) at which the first liquid droplet forms when a gas (vapor) is cooled (or
compressed).

Distillate – The vapor from the top of a distillation column is usually condensed by a total
or partial condenser. Part of the condensed fluid is recycled into the column (reflux) while
the remaining fluid collected for further separation or as final product is known as distillate
or overhead product.

Equation of state – A relation between the pressure, volume and temperature of a

system, from which other thermodynamic properties may be derived. The relation
employs any number of ‘constants’ specific to the system. For example, for a pure
component, the constants may be generalized functions of critical temperature, critical
pressure and acentric factor, while for a mixture, mixing rules (which may be dependent
on composition or density), are also used.

This design guideline are believed to be as accurate as possible, but are very general not for specific design cases. They
were designed for engineers to do preliminary designs and process specification sheets. The final design must always be
guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up
front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers
or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 20 of 103
Kolmetz Handbook
KLM Technology of Process Equipment Design Rev: 04
Group
Practical Engineering Distillation Column
Guidelines for Processing
Plant Solutions
Selection, Sizing
and Troubleshooting June 2013
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINES)

Heavy key – The heavier (less volatile) of the two key components. Heavy key is
collected at the bottoms. All non-key components heavier than the heavy key are known
as the heavy components.

Key component – A distillation column is assigned with two key components. The key
components in the feed are the main components to be separated in that column. The
volatility of the two key components must be in adjacent order when the volatilities of all
the components in the feed are arranged in either ascending or descending order.

K-value – Vapor-liquid equilibrium constant or distribution coefficient. It is used in non-

ideal (hydrocarbon) systems.

Light key – The lighter (more volatile) of the two key components. Light key is collected
at the distillate. All non-key components lighter than the light key are known as the light
components.

Reboiler –Is a heat exchanger typically used to provide heat to the bottom of industrial
distillation columns. They boil the liquid from the bottom of a distillation column to
generate vapors which are returned to the column to drive the distillation separation.

Reflux ratio – The ratio of the reflux stream to the distillate. The operating reflux ratio
could affect the number of theoretical stages and the duties of reboiler and condenser.

Relative volatility – Relative volatility is defined as the ratio of the concentration of one
component in the vapor over the concentration of that component in the liquid divided by
the ratio of the concentration of a second component in the vapor over the concentration
of that second component in the liquid. For an ideal system, relative volatility is the ratio of
vapor pressures i.e. α = P2/P1

Vapor-liquid equilibrium- Abbreviated as VLE by some, is a condition where a liquid

and its vapor (gas phase) are in equilibrium with each other, a condition or state where
the rate of evaporation (liquid changing to vapor) equals the rate of condensation (vapor
changing to liquid) on a molecular level such that there is no net (overall) vapor-liquid
interconversion

This design guideline are believed to be as accurate as possible, but are very general not for specific design cases. They
were designed for engineers to do preliminary designs and process specification sheets. The final design must always be
guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up
front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers
or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 21 of 103
Kolmetz Handbook
KLM Technology of Process Equipment Design Rev: 04
Group
Practical Engineering Distillation Column
Guidelines for Processing
Plant Solutions
Selection, Sizing
and Troubleshooting June 2013
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINES)

Vapor pressure – The pressure exerted by the vapor phase that is in equilibrium with the
liquid phase in a closed system. For moderate temperature ranges, the vapor pressure at
a given temperature can be estimated using the Antoine equation.

Weir loading – The normalized liquid flow rate leaving a tray pass divided by the length
of the outlet weir of the same pass.

Open area - The ratio of the hole area divided by the bubbling area.

Constriction factor at the bottom downcomer - The ratio of the outlet weir length over the
tower diameter.

The downcomer clearance - The distance between the bottom edge of the downcomer
apron and the tray deck

NOMENCLATURE

B Bottom product rate, moles/unit time

b Bottoms product flow rate, ft3/min
C Coefficient, ft/hr
CFS Vapor loading, ft3/s
D Distillate product rate, moles/unit time
DT Tower diameter, ft
d Distillate flow rate, ft3/min
F Feed rate, moles/unit time
fi Fugacity of component i
H Tower height, ft
HBP Enthalpy of bubble point feed stream, Btu/hr
HVF Enthalpy of vaporized feed stream, Btu/hr
K Vapor-liquid equilibrium constant
Lo Reflux liquid, moles/unit time
LR Liquid molar rate in the rectification section
LS Liquid molar rate in the stripping section
N Number of theoretical stages

This design guideline are believed to be as accurate as possible, but are very general not for specific design cases. They
were designed for engineers to do preliminary designs and process specification sheets. The final design must always be
guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up
front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers
or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 22 of 103
Kolmetz Handbook
KLM Technology of Process Equipment Design Rev: 04
Group
Practical Engineering Distillation Column
Guidelines for Processing
Plant Solutions
Selection, Sizing
and Troubleshooting June 2013
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINES)

Nm Minimum number of theoretical stages

P Total system pressure, psi
P* Vapor pressure, psi
Q Reboiler duty, Btu/hr
Qc Condenser duty, Btu/hr
q Thermal condition of feed
V1 Vapor rate at overhead column, moles/unit time
Vcalc Calculated vapor rate, moles/unit time
Vcorr Corrected vapor rate, moles/unit time
Vmax Maximum volumetric flow rate, ft3/hr
vmax Maximum velocity, ft/hr
R Reflux ratio
Rm Minimum reflux ratio
SF Separation factor,
T Temperature, oF
x Mole fraction in the liquid phase
XB Bottom liquid rate, moles/unit time
xd Mole fraction in the distillate
XDi Mole fraction of component i in the distillate
XD Distillate liquid rate, moles/unit time
xf Mole fraction in the feed
XFi Mole fraction of component i in the feed
xw Mole fraction in the bottoms
y Mole fraction in the vapor phase

This design guideline are believed to be as accurate as possible, but are very general not for specific design cases. They
were designed for engineers to do preliminary designs and process specification sheets. The final design must always be
guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up
front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers
or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 23 of 103
Kolmetz Handbook
KLM Technology of Process Equipment Design Rev: 04
Group
Practical Engineering Distillation Column
Guidelines for Processing
Plant Solutions
Selection, Sizing
and Troubleshooting June 2013
www.klmtechgroup.com
(ENGINEERING DESIGN GUIDELINES)

Greek letters

α relative volatility
γ activity coefficient
φ vapor phase fugacity coefficient
β volatility factor
ρ density, Ib/ft3

Superscripts

L liquid phase
V vapor phase
b exponent

Subscripts

avg average
bottom bottom section of column
HHK heavy component
HK heavy key
i component i
j component j
LK light key
LLK light component
top top section of column

This design guideline are believed to be as accurate as possible, but are very general not for specific design cases. They
were designed for engineers to do preliminary designs and process specification sheets. The final design must always be
guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up
front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers
or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.