CONTINUOUS COLUMN DESIGN(BINARY SY

CLIENT: M/s Talli Godavari, Hyderabad

SYSTEM: Methanol Recovery from Methanol-Toluene- Water system.

FEED/DAY(L): 4000
20% EXCESS(L) 4800

TOP BOIL UP PROPERTIES

FEED B.P M.W FEED
COMPONENTS (°C) (Kg/Kg mol) (w/w%) (mol%)
Methanol 64 32 27 17.23
Water 100 18.01 73 82.77

Distillation Time 20 hrs

Feed Rate 226 Kg/hr

INTERCEPT 0.2031 Reflux Ratio 6

Minimum Reflux 0.77 Intercept 0.0514
Number of Stages 27

CALCULATION OF VAPOUR MASS FLOW RATE:

Composition of Boil up (w/w%)
Acetone 50
Water 50
Reflux Ratio 6
L/G 0.8571
Average temperature of gas 82.0000 °C
Density of Liquid 895.0000 Kg/m3
Moles of Distillate/100 g Distillate 4.3387 moles
Operating Pressure 760 mm Hg
Average MW of Distillate 23.0482 Kg/Kmol
Density of Gas 0.7918 Kg/m3
X Intercept 0.0255
Ordinate 0.3100
1" Ceramic Intallox Saddles 98
Viscosity of Liquid 0.7450 cp
0.0007 Kg/m sec
Gas Flow rate at Flooding-G' 2.1452 Kg/m2-sec
at 70% flooding 1.5017 Kg/m2-sec

STRUCTURED PACKINGS

MELLAPAK 250Y MELLAPAK 500Y

Flow Parameter 0.025 Flow Parameter 0.025
Cg, max 0.130 Cg, max 0.130
Cg 0.104 Cg 0.104
Correction Factor 1 Correction Factor 0.7
g 2.767 Kg/m2.s g 1.937
Boil up Rate G 847.571 Kg/hr Boil up Rate G 847.571
0.235 Kg/sec 0.235
36.774 Kgmol/hr 36.774
Area of Column 0.085 m2 Area of Column 0.122
Column Diameter 329.213 mm Column Diameter 393.485
Temperature 355 °K Temperature 355
Pressure 1013 m bar Pressure 1013
F Factor 3.1116 F Factor 2.178
NTSM 2.5 NTSM 4
Height 14.04 m Height 8.78
Pressure Drop 3.5 mbar/m Pressure Drop 2.5
Total Pressure Drop 49.14 mbar Total Pressure Drop 21.94
36.856 mm Hg 16.45

BOTTOM BOIL UP PROPERTIES

FEED B.P M.W BOTTOMS
COMPONENTS (°C) (Kg/Kg mol) (w/w%) (mol%)
Methanol 64 32 0.5 0.28
Water 100 18.01 99.5 99.72

Number of Stages: 6

CALCULATION OF VAPOUR MASS FLOW RATE

Composition of Boil up (w/w%)
Methanol 0.5
Water 99.5
L/G 1.16
Average temp. of gas 99.82 °C
Density of Liquid 996.97 Kg/m3
Moles in Bottom/100 g Bottoms 5.54 moles
Operating Pressure 790 mm Hg
Average Molecular Weight of Boilup 18.05 Kg/Kmol
Density og gas 0.614 Kg/m3
X axis 0.029
Ordinate 0.31
1'' Ceramic Intallox Saddles 98
Viscosity of Liquid 0.889 cp
0.00088855 kg/m sec
Gas Flow rate at Flooding 1.97616551798351 Kg/m2-sec
At 70% Flooding 1.38331586258846 Kg/m2-sec

STRUCTURED PACKINGS

MELLAPAK 250Y MELLAPAK 500Y

Flow Parameter 0.029 Flow Parameter 0.029
Cg, max 0.13 Cg, max 0.13
Cg 0.104 Cg 0.104
Correction Factor 1 Correction Factor 0.7
g 2.572 Kg/m2.s g 1.800
Boil up Rate G 252.69 Kg/hr Boil up Rate G 252.69
0.070 Kg/sec 0.070
14 Kmol/hr 14
Area of Column 0.027 m2 Area of Column 0.039
Column Diameter 186 mm Column Diameter 223
Temperature 372.82 °K Temperature 372.82
Pressure 1053.30 m bar Pressure 1053.299
F Factor 3.2840 F Factor 2.2988
NTSM 2.4 NTSM 4
Height 3.25 m Height 1.95
Pressure Drop 1.8 mbar/m Pressure Drop 3
Total Pressure Drop 5.85 mbar Total Pressure Drop 5.85
7.800 mm Hg 4.388
MN DESIGN(BINARY SYSTEM)

DATE 30/3/2012
PREPARED BY: Devayani
CHECKED BY: Santhosh
APPROVED BY: NSW

DISTILLATE BOTTOMS Density

(w/w%) (mol%) (w/w%) (mol%) (g/cc)
50 36.01 0.5 0.28 0.792
50 63.99 99.5 99.72 0.998
0.94238

COLUMN DIAMETER CALCULATION (RANDOM PACKINGS)

Maximum Distillate Rate 121.1 Kg/hr
5.3 Kgmol/hr
Boil up rate 847.6 Kg/hr
0.2 Kg/sec
36.8 Kgmol/hr
Latent Heat of Vapourisation 401.5 Kcal/Kg
Heat Load 340299.7 Kcal/hr
Area of Column 0.2 m2
Diameter of Column 447 mm

CONDENSER AREA
Heat Load 340299.7 Kcal/hr
Temperature at the top 82.0 °C
Cooling Water Inlet Temp. 32.0 °C
Cooling Water Outlet Temp. 37.0 °C
LMTD 47.5 °C
Overall Heat Transfer Coefficient (U) 500.0 kcal/hr-m2-c
Main Condenser Area 14.3 m2
Vent Condenser Area 1.4 m2
Cooling Water Req. for Main Condenser 68.1 m3/hr
Cooling Water Req. for Vent Condenser 6.8 m3/hr
Total Cooling Water Requirement 75 m3/hr

MELLAPAK 750Y
 Flow Parameter 0.025
Cg, max 0.130
Cg 0.104
Correction Factor 0.63
Kg/m2.s g 1.743 Kg/m2.s
Kg/hr Boil up Rate G 847.571 Kg/hr
Kg/sec 0.235 Kg/sec
Kgmol/hr 36.774 Kgmol/hr
m2 Area of Column 0.135 m2
mm Column Diameter 414.769 mm
°K Temperature 355 °K
m bar Pressure 1013 m bar
F Factor 1.96
NTSM 5.3
m Height 6.62 m
mbar/m Pressure Drop 6 mbar/m
mbar Total Pressure Drop 39.74 mbar
mm Hg 29.80 mm Hg

Density Latent Heat Viscosity F (Kmol/hr) 11.08

(g/cc) (Kcal/Kg) (cp) R (Kmol/hr) 31.52
0.792 263.00 0.6 L (Kmol/hr) 42.60
0.998 540 0.89 G (Kmol/hr) 36.773857179
538.62 0.889 L/G 1.16

COLUMN DIAMETER CALCULATION

Boilup Rate 14 Kgmol/hr

252.69 Kg/hr
0.07 Kg/sec
Latent Heat of Vapourisation 538.62 Kcal/Kg
Heat Load 136103.90 Kcal/hr
Area of the column 0.051 m2
Diameter of Column 254 mm

REBOILER
Heat Load 136103.90 Kcal/hr
Temperature at bottom 99.82 °C
Steam Pressure 3 kg/cm2.g
Temperature of steam 133.54 °C
Latent Heat 516.68 Kcal/hr
Overall Heat Transfer Coefficient(U) 488 Kcal/hr-m2-C
Area of Reboiler 8.27 m2
 Steam Required 263 Kg/hr
Total Steam Requirement 316 Kg/hr

500Y MELLAPAK 750Y

Flow Parameter 0.029
Cg, max 0.13
Cg 0.104
Correction Factor 0.63
Kg/m2.s g 1.620 Kg/m2.s
Kg/hr Boil up Rate G 252.69 Kg/hr
Kg/sec 0.070 Kg/sec
Kmol/hr 14 Kmol/hr
m2 Area of Column 0.043 m2
mm Column Diameter 235 mm
Temperature 372.82
Pressure 1053.299
F Factor 2.069
NTSM 5
m Height 1.56
mbar/m Pressure Drop 2.5 mbar/m
mbar Total Pressure Drop 3.9 mbar
mm Hg 5.200 mmHg
Pressure Drop=1 inch water column/foot packing for atmospheric columns.

Latent Heat Viscosity

(Kcal/Kg) (cp)
263.00 0.6
540 0.89
401.5 0.745
PRESSURE PRESSURE °C Kcal/Kg FP Cg max
1 Kg/cm2-g Temp Latent heat 0.01 0.15
1.5 0.02 17.51 587.61 0.0125 0.15
2 0.03 24.1 583.89 0.015 0.14
2.5 0.04 28.98 581.14 0.0175 0.14
3 0.05 32.9 578.92 0.02 0.135
3.5 0.06 36.18 577.05 0.025 0.13
4 0.07 39.02 575.44 0.03 0.125
4.5 0.08 41.53 574.01 0.035 0.12
5 0.09 43.79 572.72 0.04 0.115
0.1 45.83 571.54 0.045 0.11
0.2 60.09 563.3 0.05 0.105
0.3 69.13 557.97 0.06 0.1
0.4 75.89 553.94 0.07 0.095
0.5 81.35 550.64 0.08 0.09
0.6 85.95 547.83 0.09 0.085
0.7 89.96 545.36 0.1 0.085
0.8 93.51 543.15
0.9 96.71 541.14
1 99.63 539.3 MELLAPAK 500Y
1.1 102.32 537.59 F Factor NTSM
1.2 104.81 535.99 0.6 4.4
1.3 107.13 534.49 0.7 4.4
1.4 109.32 533.07 0.8 4.4
1.5 111.37 531.73 0.9 4.3
1.5 111.37 531.73 1 4.3
1.6 113.32 530.45 1.1 4.2
1.7 115.17 529.22 1.2 4.2
1.8 116.93 528.05 1.3 4.2
1.9 118.62 526.92 1.4 4.2
2 120.23 525.84 1.5 4.2
2.2 123.27 523.78 1.6 4.2
2.4 126.09 521.86 1.7 4.2
2.6 128.73 520.04 1.8 4.1
2.8 131.2 518.32 1.9 4.1
3 133.54 516.68 2 4
3.5 138.87 512.89
4 143.63 509.45 MELLAPAK 750Y
4.5 147.92 506.29 F Factor NTSM
5 151.85 503.35 0.6 5.7
5.5 155.47 500.6 0.7 5.7
6 158.84 498 0.8 5.7
6.5 161.99 495.54 0.9 5.7
7 164.96 493.2 1 5.7
7.5 167.76 490.96 1.2 5.6
8 170.42 488.8 1.4 5.6
8.5 172.94 486.73 1.6 5.6
9 175.36 484.74 1.8 5.3
9.5 177.67 482.8 2 5
10 179.88 480.93 2.25 4.8
11 184.06 477.35
12 187.96 473.94
13 191.6 470.7
14 195.04 467.6
15 198.28 464.61
16 201.37 461.74
17 204.3 458.95
18 207.11 456.26
19 209.79 453.64
20 212.37 451.1
21 214.85 448.61
22 217.24 446.19
23 219.55 443.82
24 221.78 441.5
25 223.94 439.23
26 226.03 437.01
27 228.06 434.82
28 230.04 432.67
29 231.96 430.56
30 233.84 428.48
 X axis Ordinate
PACKINGS Correction Factor 0.02 0.32
MELLAPAK 125X 1.5 0.025 0.31
MELLAPAK 125Y 1.25 0.03 0.3
MELLAPAK 170X 1.51 0.035 0.3
MELLAPAK 170Y 1.1 0.04 0.28
MELLAPAK M2X 1.41 0.045 0.28
MELLAPAK M2Y 1.09 0.05 0.27
MELLAPAK 250X 1.25 0.055 0.27
MELLAPAK 250Y 1 0.06 0.26
MELLAPAK 350Y 0.85 0.065 0.26
MELLAPAK 500X 1 0.07 0.25
MELLAPAK 500Y 0.7 0.075 0.24
MELLAPAK 750Y 0.63 0.08 0.23
SULZER BX 1 0.085 0.23
PACKING CY 0.65 0.09 0.22
PACKING KERAPAK 0.8 0.095 0.22
0.1 0.21
0.125 0.19
MELLAPAK 250Y 0.15 0.17
F Factor NTSM 0.175 0.15
0.6 3.2 0.2 0.14
0.7 3.15 0.25 0.125
0.8 3.1 0.3 0.1
0.9 3.05 0.35 0.09
1 3 0.4 0.08
1.2 3 0.5 0.065
1.4 2.9 0.6 0.055
1.6 2.85 0.7 0.045
1.8 2.8 0.8 0.04
2 2.75 0.9 0.036
2.25 2.7 1 0.033
2.5 2.6 1.25 0.025
2.75 2.6 1.5 0.02
3 2.5 1.75 0.0175
3.25 2.4 2 0.0145
3.5 2.2 2.5 0.012
3.75 2 3 0.008
4 1.8 3.5 0.007
4.5 1.3 4 0.0058
5 0.0042
6 0.0032
7 0.0026
8 0.002
9 0.00175
10 0.0015