Introduction to

Process Engineering

and

Design

Shuchen B.Thakore
Assistant Professor of Chemical Engineering
L D College of Engineering
Ahmedabad, Gujarat

Bharat I. Bhatt
Consulting Engineer
Aavishkar Consultancy Services
Ahmedabad
Process Engineering Channel

■
@ProcessEng

Tata McGraw-Hill Publishing Company Limited

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 Introduction to

Process Engineering

and

Design
Process Engineering Channel
@ProcessEng
 About the Authors

Shuchen B. Thakore is Assistant Professor of Chemical Engineering at L D

College of Engineering, Ahmedabad, Gujarat. He has been teaching undergraduate
and postgraduate students in chemical engineering, for more than 10 years. Besides
teaching, he also undertakes consulting assignments in process and mechanical
design of heat exchangers, distillation columns, storage tanks, pressure vessels,
etc. and environmental audit for various chemical industries.
Prior to joining the academic institute, he worked in the industry for about 5
years. He served Alembic Chemical Works, Naveen Heat Exchangers Ltd., Gujarat
Alcohol and Allied Chemicals Ltd. and Indian Engineering Software Co.
Mr. Thakore has earlier authored a book on Illustrated Process Equipment
Design, a publication of Atul Prakashan, Ahmedabad.
Mr. Thakore graduated in Chemical Engineering from Gujarat University and
did his M. E. in Chemical Engineering from M. S. University, Vadodara.

Bharat I. Bhatt is a Consulting Engineer to Chemical Industries for the last

three years and is based at Ahmedabad. His firm, Aavishkar Consultancy Services,
provides consulting services in debottlenecking in chemical industries, energy
conservation, effiuent treatment, etc. He earlier served chemical industries for
nearly 34 years. His industrial experience covered the fields of project execution,
process engineering, debottlenecking, troubleshooting, production management,
management reporting, etc. He spent nearly 18 years with Indian Farmers Fertiliser
Cooperative Limited (1FFCO), Kalol Unit in various capacities. Prior to joining
the industry, he served at the reputed textile research institute (ATIRA) for nearly
5 years where he was involved in industrial research and consultation to member
textile units. He also worked in many fine chemical and pharmaceutical industries
as Vice President (Technical).
Mr. Bhatt has also authored a book titled Stoichiometry, published by Tata
McGraw-Hill Publishing Co. Ltd., New Delhi. Till date, four editions are published
of which the last two editions were in SI Units. In addition, Mr. Bhatt carried out
Process Engineering Channel

units conversion work from EPS units to SI units of the book Introduction to
Chemical Engineering Thermodynamics, 6th Edition, by Smith, Van Ness and
Abbott, a publication of McGraw-Hill, USA. Another book titled, Design Data
Book: Properties of Steam, Selected Refrigerants, n-Hexane and Brines (SI units),
by Mr. Bhatt is published by CBS Publishers and Distributors, New Delhi.
Mr. Bhatt graduated in Chemical Engineering from the University Institute of
@ProcessEng

Chemical Technology, University of Mumbai.

 Introduction to

Process Engineering

and

Design

Shuchen B.Thakore
Assistant Professor of Chemical Engineering
L D College of Engineering
Ahmedabad, Gujarat

Bharat I. Bhatt
Consulting Engineer
Aavishkar Consultancy Services
Ahmedabad
Process Engineering Channel

■
@ProcessEng

Tata McGraw-Hill Publishing Company Limited

NEW DELHI

McGraw-Hill Offices
New Delhi New York St Louis San Francisco Auckland Bogota Caracas
Kuala Lumpur Lisbon London Madrid Mexico City Milan Montreal
San Juan Santiago Singapore Sydney Tokyo Toronto
 n
Tata McGraw-Hill

Published by the Tata McGraw-Hill Publishing Company Limited,

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 Contents

Foreword ix
Preface xi

1. Dimensions and Units 1

1.1 Introduction 1
1.2 Fundamental Quantities or Dimensions 1
1.3 Derived Units 2
1.4 Recommended Rules for Writing Unit Symbols 7
1.5 Conversion Factors 9
References 9

2. Stoichiometry 10
2.1 Introduction 10
2.2 Basic Chemical Calculations 10
2.3 Energy Balances 19
2.4 Enthalpy Changes Accompanying Chemical Reactions 21
2.5 Fleat Changes in Mixing Processes 27
Exercises 32
References 37

3. Process Engineering 38
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3.1 Introduction 38
3.2 Examples of Alternative Routes in Process Engineering 38
3.3 Generalized Approach to the Chemical Plant Design 39
3.4 Preparation of Operating Instructions Manual 45
3.5 Conductance of Performance Test Runs 46
3.6 Troubleshooting 47
@ProcessEng

3.7 Cost Cutting Measures 47

3.8 Green Engineering 48
3.9 Process Intensification 50
3.10 Conclusion 52
Exercises 52
References 53
 vi Contents

Importance of Process Diagrams in Process Engineering 54

4.1 Introduction 54
4.2 Need for PFD and P&ID 54
4.3 Block Diagrams 55
4.4 Development and Utility of Process Flow Diagrams 55
4.5 Development of Piping and Instrumentation Diagrams 60
4.6 Conclusion 67
Exercises 67
References 69

Process Design of Piping, Fluid Moving Devices and Flow Meters 70

5.1 Introduction 70
5.2 Process Design of Piping 70
5.3 Process Design of Fluid Moving Devices 83
5.4 Evaluation of Centrifugal Pump Performance
when Handling Viscous Liquids 101
5.5 Power Required in Fan, Blower and in
Adiabatic Compressor 105
5.6 Flow Meters 110
5.7 Process Design of Orifice Meter 115
5.8 Process Design of Rotameter 119
5.9 Two Phase Flow 127
5.10 Troubleshooting of Fluid Flow Systems 130
Exercises 130
References 133

Process Design of Heat Exchangers 134

6.1 Shell and Tube Heat Exchanger 134
6.2 Design of Heat Exchangers 137
6.3 General Design Method for Shell and Tube Heat Exchanger 155
6.4 Criteria of Selection between Horizontal Condenser and
Vertical Condenser 182
6.5 Condensation with Non-condensables 192
6.6 Multicomponent Condensation 200
6.7 Process Design of Reboilers and Vaporizers 217
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6.8 Tinker's Flow Model 247

6.9 Air Cooled Heat Exchangers and Air Heaters 249
6.10 Plate Heat Exchangers 270
6.11 Spiral Flow Heat Exchangers 281
6.12 Brazed Aluminium Plate-fin Heat Exchanger 294
6.13 Heat Exchanger Networking for Energy Integration 295
6.14 Heat Transfer in Solids 311
@ProcessEng

Exercises 321
References 324

Design of Liquid-Liquid Extractor 325

7.1 Introduction 325
7.2 Important Industrial Applications of Liquid-Liquid
Extraction 326
 Contents vii

7.3 Phase Equilibrium 326

7.4 Desirable Solvent Properties or Choice of Solvent 327
7.5 Design of Counter Current Multistage Extractor 329
7.6 Industrially Important Extractors 342
7.7 Supercritical Extraction (SCE) 364
Exercises 375
References 377

8. Process Design of Distillation Columns 378

8.1 Introduction 378
8.2 Criteria of Selection 378
8.3 Selection of Equipment for Distillation 379
8.4 Distillation Column Design 380
8.5 Batch Distillation 475
8.6 Short Path Distillation 493
8.7 Reactive and Catalytic Distillation 501
8.8 Azeotropes and Separation Thereof 512
8.9 Energy Conservation in Distillation 538
Exercises 556
References 565

9. Process Design of Absorbers 567

9.1 Introduction 567
9.2 Criteria of Selection 568
9.3 Design of Packed Tower Type Absorber 569
9.4 Process Design of Spray Chamber or Spray Tower Type
Absorber 606
9.5 Venturi Scrubber 611
9.6 Process Design of Falling Film Absorber 615
Exercises 654
References 656

10. Process Design of Reactors 657

10.1 Introduction 657
10.2 Different Types of Reactors 657
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10.3 Batch Reactor 658

10.4 Continuous Flow Reactors 67/
10.5 Degree of Completion of Reaction 682
10.6 Mixing for the Different Type of Reaction Systems 684
10.7 Bubble Column Reactor 697
10.8 Design of Fixed Catalyst Bed Reactors for Gaseous Reactions 713
@ProcessEng

Exercises 725
References 728

Appendix 1 Conversion Tables 730

Appendix 2 Viscometer Conversion Chart 735

Index 736
Process Engineering Channel
@ProcessEng
 Foreword

Dr. Jack Welch, CEO of General Electric, built its market cap by more than $450
billion and established himself as the most admired business leader in the world.
He is Doctorate in Chemical Engineering and is proud to be a Chemical Engi-
neer. In his business autobiography he wrote, "I have always felt that chemical
engineering was one of the best backgrounds for a business career because both
the class-work and required thesis teach you one very important lesson: There
are no finite answers to many questions."
A chemical process engineer's job is, therefore, tough. It is hard because he
has to find not only a finite answer but to select the best answer for the situation
from a variety of options. That is why process engineering is interesting and at
the same time intriguing.
A process engineer has to design a plant or a part of it. He may have to design
a unit operation or a unit process or a system. The important aspect is that it must
work and operate reliably and smoothly. The unit is to be designed for a commer-
cial purpose and, hence, it has to be economical and cost effective. A good proc-
ess engineer has to have plant experience and, in addition, a good understanding
of process economics and knowledge of current costs and trends.
Chemical process industry covers a very wide spectrum of industrial products.
Apart from the chemicals they handle, the quantities and sizes also vary. This
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requires the process engineer to have flexibility of mind and vision to adopt itself
to any scale. Selection and design of the equipment should therefore be capable
to handle the capacities and instruments to measure the parameters for large chemi-
cal plants to micro units to manufacture enzymes.
Till 1973, fuel and energy costs were a small component of the manufacturing
costs of a chemical product. Since then, the rising fuel prices have made it man-
datory that the plant design and its operation be energy efficient. The approach to
@ProcessEng

process design has undergone a paradigm change.

Bhopal gas leakage disaster and Chernobyl catastrophe made another impact
on the minds of process engineers and changed the practices followed till then.
Greater responsibility now rests on the process engineers for safer designs of the
plants. HAZAN (Hazard Analysis) and HAZOP (Hazard and Operatability) studies
have become a part of process studies, attaching one more design aspect in the
 Foreword

minds of process engineers. Several lessons regarding storage and handling were
learnt by the process engineer. He has to now respect environmental and ecologi-
cal sustainability of the process and its design.
Software for the design of equipment such as heat exchangers, distillation
columns, etc. are available. It has simplified piping design. Drawing and drafting
has become easier, error free and faster. But without understanding the design
principles, explained in this book, one cannot use them efficiently.
Yet, the process flow sheeting or the development of a process scheme still
remains a brain teasing function. It can be explained and perhaps taught but can-
not be standardized. Process engineer has to be innovative and creative. Prepara-
tion of a Process Flow Diagram is still a prominent and challenging domain of a
process engineer.
It is more admirable that Mr. Bharat I. Bhatl and Prof. Shuchen B. Thakore
decided to go deeper into some of these topics and write a book on Process Engi-
neering and Design. They have done it with success. I had the opportunity of
working with Mr. Bhatt. He is one of the best process engineers I have come
across. The long industrial experience of Mr. Bhatt and extensive teaching expe-
rience of Prof. Thakore have made them eminently suitable to offer their knowl-
edge to student fraternity and practicing engineers. I have no doubt that the book
will find its place with most academicians involved in teaching the subject.
The book describes systematic methods for the process design with many il-
lustrations, drawn from various sections of the industry. They have included sev-
eral solved and unsolved problems with sufficient details. Authors' approach is
user friendly and result oriented. Indepth study of these examples will boost con-
fidence of the students in solving real life design and operating problems.
Large number of references, cited at the end of each chapter, indicates the
extensive literature study made by the authors. Further, study of these references
will provide more insight to process design aspects.
An exclusive chapter is devoted on development of Process Flow Diagrams
(PFD) and Piping and Instrumentation Diagrams (P&ID) which is justified by
my earlier comments. Sufficient emphasis is placed on 'green' engineering. These
aspects have made this book unique.
Many recent topics like pinch technology, energy conservation in distillation,
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two-phase flow of fluids, design of loop reactors and many others are to be ap-
preciated which are hard to find in other books on process design.
I have no doubt that the book will make the library of a student and practicing
engineer richer.

Suhas M Mokashi
Ex-Director of Technology & Marketing
@ProcessEng

Kaevernar Powergas Pvt. Ltd.

 Preface

has helped in deciding the appropriate coverage in the book for the course sylla-
bus. Prior to his teaching experience, he worked as a process engineer in indus-
tries for five years. Thereafter he worked as a consultant for process design of
various chemical equipment. Few problems covered in the book are derived from
his actual assignments.
Bharat Bhatt spent more than 15 years in the Process Engineering Section of a
large chemical plant. He also carried out the design of many chemical plant
equipments, which were successfully commissioned. The present work reflects
the experience gained by him during his tenure of service.

Features

• Only a limited number of unit operations are covered to highlight the proc-
ess design aspects. In each of these operations, current developments are
included which provide energy efficient, more reliable and safer designs.
Networking of heat exchangers (pinch technology), two-phase fluid flow
system, solids cooling, supercritical extraction, separation of azeotropic
mixtures, energy conservation in distillation, design of jet reactors, han-
dling of liquids saturated with gases and many other topics are covered in
the book which would be of interest of the readers in process engineering
and design.
• Use of correct property values in process design plays an important role.
Property data are extracted from various literature sources which should
help readers think of the various sources that are available for the specific
data.
• Syllabus of many universities were gathered and a sincere attempt is made
to cover most (if not all) topics of these syllabii.
• A number of ready to use software packages are available in the market.
However, we believe that basic approach to process design should be clear
to the chemical engineers. This knowledge should help the engineers to
utilize the software in an efficient manner. Use of mathematical software
(such as Mathcad®, Maple®, etc.) and spreadsheet software such as (Ex-
cel®) is made in solving many problems. Preparation of process diagrams
with Autocad® or Visio® is encouraged to enhance the skills and speedy
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execution of the project.

• Every effort has been made to make the approach to the subject student
friendly. Presentation is made in a lucid, logical and step-by-step manner.
Writing style is kept relatively simple for easy understanding. Industrial
examples are cited for each concept/principle so that the student can appre-
ciate the concept.
• A large number of solved problems are drawn from the industry to make
@ProcessEng

the book practical. The worked examples are regarded as part of the text
and are clearly explained without expecting the student to fill in missing
steps. They will give students a good understanding of the design steps and
the confidence to solve problems themselves in real life.
 Preface xiii

• A large number of exercise problems are given at the end of each chapter.
Design problems as well as problems with varying degree of difficulty are
included.
• The approach adopted in the book will enable a student to progress from
theory to practice smoothly. At the same lime a practicing process design
engineer may like to use the book as a ready reference.

Who will Benefit from this Book?

The text is an introduction to the vast subject of process design. It is intended to

provide course material for a two-semester course in process design for under-
graduate students of chemical engineering. It can be also used for the students
pursuing higher studies for M. Tech. in Process Engineering and Design. It can
serve as a reference text for other subjects like advanced separation techniques,
advanced heat and mass transfer, etc.
The main prerequisites for the course using the text are chemistry, stoichiom-
etry and unit operations. Although familiarity with computer and various soft-
ware packages will be helpful, the user friendly methodology adopted in the book
does not make knowledge of these mandatory.

Acknowledgements

We are greatly honoured by the Foreword written by Mr. S. M. Mokashi who is a

well known process design expert. His industrial and consulting experience spans
over 40 years. He has handled many large industrial projects. We are extremely
thankful for his encouragement in our scholastic work.
We have been rendered help by many of our colleagues who were also a source
of inspiration. We thank all of them for their indirect contributions. We are grate-
ful to the Principal, Vishwakarma Government Engineering College, Gandhinagar,
Gujarat for granting us the permission to publish this book. We are also thankful
to the reviewers who read the original manuscript and offered valuable com-
ments/suggestions. We would like to express our appreciation for loving support
we had received from our wives; Dimple Thakore and Minaxi Bhatt.
We want to thank many at Tata McGraw-Hill for their overwhelming support.
In particular, we wish to place on record our thanks to Ms Vibha Mahajan, Ms
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Shukti Mukherjee, Ms Mini Narayanan and Ms Anjali Razdan for their support
and encouragement.

Suggestions and Comments

Suggestions and comments of the readers are welcome to improve the utility of
the book in future. We can be reached through the publisher or directly at
@ProcessEng

sbthakore@yahoo.co.in for Shuchen Thakore and b_bhatt26@hotmail.com for

Bharat Bhatt.

Shuchen B. Thakore
Bharat I. Bhatt
 Chapter

Dimensions and

Units

1.1 INTRODUCTION

Knowledge of dimensions and units is imperative in day to day dealings. While

dimensions are recognized by our sensory perceptions, their use requires definite
scales of measurement, known as units. When a solid is observed, one thinks
about its volumetric and mass dimensions. Similarly a liquid is recognized by its
volume and density measurements. A gas exerts definite pressure and tempera-
ture which are important for defining its state.
Various quantities, required to identify a substance and its state can be classified
in two catagories; namely fundamental and derived. Every quantity can be ex-
pressed as a product of a dimensionless number and a unit where the unit is a
selected reference quantity in terms of which all quantities of the same kind can
be expressed.

1.2 FUNDAMENTAL QUANTITIES OR DIMENSIONS

Fundamental quantities or dimensions are length, mass, time, thermodynamic

temperature, electric current, amount of substance and luminous intensity. Units,
representing these quantities are known as base units.
There are basically two systems of units fps and metric. The former is widely
used in the USA and is also known as US Customary Units. It is based on foot,
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pound and second as standard measurements of length, mass and time, respectively.
Metric (mks) system is based on the unit of length, known as metre. The unit
of mass and time in this system are kilogram and second. Its important feature is
the decimal expression.
International system of units (or Le Systeme International d'Unites in French
or simply SI Units) was adopted by the 11th General Conference of Weights and
@ProcessEng

Measures in 1960. Base units of the mks system for length, mass and lime are
retained in the SI system. Base units of the other four fundamental quantities are
defined in the SI system. Table 1.1 lists the fundamental quantities in different
units.
The thermodynamic temperature (Kelvin), defined in SI, is accepted as the
absolute temperature in the metric system. For definitions of all the funamental
quantities, references 1 to 4 may be consulted.
 Introduction to Process Engineering and Design

Table I.I Fundamental Quantities

Symbol Fundamental System of units with symbolic Dimension

quantity abbreviation
SI Metric fps

1 Length Metre (m) Metre (m) Foot (ft) L

m Mass Kilogram (kg) Kilogram (kg) Pound (lb) M
e Time Second (s) Second (s) Second (s) 0
/ Electric current Ampere (A) Ampere (A) Ampere (A) I
T, t or T Temperature Kelvin (K) Celsius (0C) Fahrenheit (0F) T
n Amount of substance Mole (mol) n
K Luminous intensity Candela (cd)

In 1971 the concept of the amount of a substance was introduced as a funda-

mental quantitiy. It is defined as the amount of substance of system containing as
many elementry entities as the number of atoms in 0.012 kilogram of carbon-12
element. This unit of quantity was called a mo/e (abbreviated as mol). Thus uni-
fied scale of mole gives value of the relative atomic mass (m). When a compound
is represented by a chemical formula, then the total mass computed based on the
formula is called molar mass (popularly known as molecular weight) and is
represented by symbol M.

1.3 DERIVED UNITS

Derived units (including supplementary units) are expressed algebraically and in

terms of base units by means of mathematical signs of multiplicaiton and divi-
sion. For example, the SI unit of work or energy is Joule which is defined as work
done when one Newton (N) force acting on a body moves it by a distance of one
metre (see Sec. 1.3.4).
Table 1.2 lists some of the important SI derived units used in Chemical Engi-
neering with their special names while Table 1.3 lists frequently used derived
units.

Table 1.2 SI Derived Units with Special Names. Including SI Supplementary Units
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SI Derived Unit Expressed in Terms of SI Base

(Derived Quantity) Special Name Symbol Units and SI Derived Units
Plane angle radian a, p, y 1 rad = Im/m = 1
Solid angle steradian £2, vv 1 sr = lm2/m2= 1
Frequency hertz / 1 Hz =1 s-1
Force netwon F 1 N = 1 kg ■ m/s2
Pa = 1 N/m2
@ProcessEng

Pressure or stress pascal P'P 1

Energy or work or joule E, H I J= 1 N■m
Quantity of heat
Power watt 1 W = 1 J/s
Radiant flux
Electric charge or coulomb Q. I C=1 A s
Quantity of electricity
(Contd.)
 Dimensions and Units 3

Table 1.2 (Could.)

SI Derived Unit Expressed in Terms of SI Base

(Derived Quantity) Special Name Symbol Units and SI Derived Units

Electric potential or volt V 1 V = 1 W/A

Potential difference, or
Tension or
Electromotive force
Electric resistance ohm R 1 G = 1 V/A
Electric conductance Siemens G = i/r i s = i ir1
Celsius temperature degree Celsius1 t 10C = 1 K

'Degree Celsius is a special name for the unit Kelvin for use in stating value of Celsius tem-
perature. r/0C = UK - 273.15.

Table 1.3 Additional Frequently Used SI Derived Units

Quantity Symbol SI Unit Practical Units Notes

Acceleration a m/s2 m/s2, cm/s2
Acceleration of free 8 m/s2 m/s2
fall
Isentropic exponent ^ cp/cv
(for ideal gas)
Ambient Pressure Pamb N/m2, Pa mbar, bar
Angular acceleration a rad /s2 rad/s2
Angular velocity (0 rad /s rad/s
Area A, A^, S, a m2 m ? , cm?
Concentration of CB mol /m3 mol/m3, mol/L
substance B
Current density, j A/m2 A/m2, A/cm2
Density (mass P kg An3 kg/m3, g/cm3,
concentration) kg/L
Relative density / d P'JP'2 — Non-dimensional
Specific gravity quantity
Diameter d, D m cm. mm
Diffusion D m2/s m2/s, cm2/s
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coefficient
Efficiency n — — Non-dimensional
quantity
Heat (enthalpy) of A J/g, J/mol kJ/kg. kJ/kmol
evaporation
Molar flow rate/ dv mol/s, m3/h mol/s, m3/h,
Volumetric flow rate m3/s
@ProcessEng

mbar • L
Gas constant (molar) R J/(mol ■ K)
(mol • K)
(m3 • bar)/(kmol - K)
(Contd.)
 4 Introduction to Process Engineering and Design

Table 1.3 (Could.)

Quantity Symbol SI Unit Practical Units Notes

mbar • L
Gas constant of RR J/(kg • K)
(kg-K)
substance B
(specific) (m3 • bar)/(kg ■ K)
Heat capacity of a C J/K J/K, kJ/K
given mass
Heat capacity, Cmp J/(mol • K) kJ/(kmol • K)
isobaric, molar
Heat capacity. cP,cL J/(kg • K) J/(kg • K)
isobaric, specific
Heat capacity, Cmv J/(mol ■ K) kJ/(kmol • K)
isochoric; molar
Heat flow rate or 0 W, J/s kW, kJ/s, kJ/h
heat flux
Heat transfer h W/(K • m2) W/(K ■ m2),
coefficient kcal/(h • m2 • 0C)
Height h m m, cm, mm
Kinematic viscosity Y m2 /s m2/s, mm2/s,
cm2/s, cSt
Kinetic energy Ek J J
Leak rate (in a Ql N • m/s mbar ■ L/s
vacuum system)
Length L m m, cm, mm
Liner expansion a, m/(m • K), m/(m • K), 1/K
coefficient
Mass flow rate Qm ' m kg/s kg/s, kg/h, g/s
Mass fraction vv ^ r kg/kg %, ppm ppm = parts per
mega parts
Molality m mol/kg mol /kg —
Molarity mol/dm3 mol/m3. mol/L —
Molar mass M kg/kmol kg/kmol, g/mol
Molar volume V
m mVmol m3 /mol, L/mol
Number of n 1/s l/s, 1/min
revolutions (or rpm)
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Partial pressure of PB N/m2, Pa mbar, kPa, torr

component B
Period (periodic e s s, ms, (is
time)

Permeability (for Nm3 Nm3

Po
gases) (m2 ■ s ■ Pa) (m2 ■ d • bar)
@ProcessEng

Pumping speed qj m3/s L/s, m3/h

(rate)/volumetric
flow rate
Quantity of gas V Nm3 L
Quantity of heat Q.H.i J J. kJ, kWh, W ■ s
(Conld.)
 Dimensions and Units 5

Table 1.3 (Could.)

Quantity Symbol SI Unit Practical Units Notes

Radius (also of r m cm, m, pm

molecule)
Vapour pressure Pv N/m2, Pa mbar , kPa, Pa, torr
Saturation vapour
pressure Ps N/m2, Pa mbar, kPa, Pa, torr
Temperature AT, At K K,0C
difference
Thermal k W/(K • m) W/(K • m), kW/(m ■ K),
conductivity kcal/(h ■ m • 0C)
Thermal diffusivity a m2/s m2 /s
Velocity V m/s m/s, mm/s, km/h
Viscosity (dynamic) P Pa • s mPa • s, cP
Volume V m3 m3, L, cm3
Volume (specific) V m3/kg m3/kg, cm3/g
Volume fraction of <PB m3/m3 L/L, %, ppm ppm = parts
substance B per mega parts
Wavelength A m nm. A
Weight (force) G N kgf
Specific/absolute H kg/kg kg/ kg. g/g
humidity
Relative humidity RH — Non-dimen-
sional quantity
Saturation ratio <P — — - do -

It will now be appropriate to elaborate a few of the important SI derived units

for better understanding.

1.3.1 Force

According to the Newton's second law of motion,

Famxa (1.1)
or F - Km a (1-2)
where, K = proportionality constant
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Selecting K as unity, the unit netwon is defined. Thus, when a force of one
newton (N) is applied to a body having a mass of one kilogram it gives an accel-
eration of one m/s2.
Definition of technical unit of force is obtained by selecting K equivalent to
1/g where g is called Newton's law conversion factor. Its value is 9.806 65
(kg • m)/(kgf • s") and is equal to the acceleration due to gravity (g) at mean sea
level. It may be noted that gc is not equal g at all locations on the earth.
@ProcessEng

Kilogram-force (kgf) is the force which when applied to a body having a mass
of one kilogram, gives it an acceleration of 9 .806 65 m/s2. It is the base unit in
metric system of units.
1 N =0.101 972 kgf
or 1 kgf = 9.806 65 N
 Introduction to Process Engineering and Design

Although mass is the base unit, it nearly equals weight under gravitational
acceleration (g). This is why 'mass' and 'weight' terms are commonly used with-
out differentiation in general practice.

1.3.2 Pressure

Pressure is the force acting on a unit area, exposed to it.

(L3)
A
'y
Common units of pressure in SI and metric systems are N/m (known as
9 •
Pascal; symbol Pa) and kgf/crrr, respectively. Pressure, measured with the help
of a gauge, is called gauge pressure or over pressure and the letter 'g' follows the
unit. When (local) atmospheric pressure is added to the gauge pressure, it is called
absolute pressure and the letter 'a' follows the unit. Standard atmospheric pres-
sure (symbol atm) is measured at mean sea level and is assigned the value 101
325 N/m2 or Pa or 1.033 kgf /cm2. Since Pascal is a very small unit of pressure,
bar is chosen as a practical pressure unit in the SI system.
1 bar = 105 Pa = 1.019 716 kgf/cm2 = 0.986 923 atm
1 atm = 1.013 25 bar
Pressure is also expressed in terms of fluid heads; e.g. water column (WC),
liquid column (LC), mercury column (Hg), etc.
Fluid head = Pressure /density = p/p (1-4 )
1 atm = 760 mm Hg at 0oC or torr = 10.33 m WC at 40C
Vacuum refers to pressure below atmospheric pressure and hence absolute
pressure of a vacuum system is derived by substracting vacuum from atmospheric
pressure.

1.3.3 Volume

Volume is the space occupied by a substance. It is measured in cubic metres and

litres in SI and metric units, respectively. Approximately, 1 m3 = 1000 L = 1 kL.

1.3.4 Work, Energy, Power and Heat

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Work is defined as the product of force acting on a body and the distance trav-
elled by the body.
W = Fxd (1.5)
2 2
Units of work (kg • m )/s or N • m or joule (symbol J) and m • kgf in SI and
metric systems, respectively.
Internal energy (Symbol U or E) is a physical entity which is present in a
@ProcessEng

system in different forms; mechanical, chemical, thermal, etc. Heat is the form of
energy in transit that flows from higher temperature to lower temperature. Total
Enthalpy (symbol H) of a substance is the total energy possessed by it under the
given conditions.
H=U + pV (1.6)
 Dimensions and Units 7

Unit of energy, heat and enthalpy are joule and calorie (symbol cal) in SI and
metric systems, respectively.
1 calorie (International Steam Tables) = 4.1868 J
It may be noted that unit of work, energy, heat and enthalpy in SI unit is same,
i.e. W (unlike metric system).
Power P is defined as the work done per unit time

W
P=J (1.7)

Unit of power is Watt (i.e. J/s) and m • kgf/s in SI and metric systems, respec-
tively. Practical unit of power in metric system is horsepower.
1 metric system horsepower = 75 (m • kgf)/s = 0.7355 kW

1.3.5 Derived Electrical Units

Electric potential (V) is defined as

W
V= — (1.8)
/
Its unit is volts.
Resistance of the conductor is defined as

v/
R=j (1-9)

Its unit is ohms Q. Reciprocal of resistance is called conductance; symbol (G)

and has units Siemens (S). Quantity of electricity (symbol Q) is defined as the
product of current and time.
Q=I-e (1.10)
Unit of quantity of electricity is coulomb (C).
1 Faraday (F) = 96 485.309 C/mol

1.4 RECOMMENDED RULES FOR WRITING UNIT SYMBOLS

Following guidelines may be followed while using SI unit symbols.

(i) SI prefixes are given in Table 1.4.
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(ii) An exponent attached to compound prefix-unit implies that the exponent

refers to the entire compound unit and not just to the base symbol. 1 cm3
means volume of a cube having one cm side.
(iii) The product of two or more units may be indicated in any one of the follow-
ing ways.
Correct: N m, or N • m Incorrect: Nm
@ProcessEng

(iv) A solidus (oblique stroke), a horizontal line or negative powers may be

used to express a derived unit, formed from two others by division, e.g.

m
/ -i -i
m/s, —, m ■ s or m s
s
 Introduction to Process Engineering and Design

Table 1.4 SI Prefixes

Factor Prefix Symbol

I024 yotta Y
1021 zetta Z
I018 exa E
I015 peta P
1012 tera T
109 giga G
106 mega M
103 kilo k
102 hecto h
101 deca da
10-' deci d
KT2 centi c
ur3 milli m
KT6 micro 4
KT9 nano n
KT12 pico P
15
KT femto f
10-18 atto a
KT21 zepto z
4^
N>

yocto
O1

(v) A solidus must not be repeated on the same line unless ambiguity is avoided
by a parenthesis.
Correct Incorrect
0 0 0
m/s" or m • s" or m s_ m/s/s
W/(m ■ K) or W nT K
2 2 -1
W/m2 • K or W m-2/K
(vi) Unit symbols do not change in the plural. For example, 5 metres should be
abbreviated as 5 m and not as 5 ms.
(vii) Unit symbols are not followed by a full stop (period) except at the end of a
sentence.
Correct: 8 kg Incorrect: 8 kg.
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(viii) When numerical values fall outside the range of 0.1 to 1000, it is recom-
mended that the numerals be separated into groups of three with a space
replacing the traditional comma.
Recommended Not recommended
3 600 or 3600 3,600
19 625 725 19,625,725
@ProcessEng

0.001 625 0.001,625

0.046 89 0.046,89
In this book, four digits or decimals are grouped.
(ix) Prefix symbols are printed without any space between the prefix symbol
and the unit symbol.
Correct: 10 kW Incorrect: 10.5 kW
 Dimensions and Units 9

(x) Compound prefixed formed by the juxtaposition of two or more SI prefixes

are not to be used.
Correct: 6 GJ Incorrect: 6 MkJ
(xi) A prefix should never be used alone.
Correct: 106/m3 Incorrect: M/m3
(xii) Although kilogram is the base unit in SI units, names of decimal multiples
and sub-multiples of mass are formed by attaching prefixes to the word
'gram'.
Correct: 1 mg Incorrect: 1 pkg
(xiii) Good practice recommends selection of a prefix which, whenever possible,
provides a numerical value between 0.1 and 1000. Prefer expression 10.0
kPa over 0.01 MPa. However, when values are tabulated, they should be
expressed in the same unit multiple even though their numerical value lies
outside 0.1 to 1000 range.
12 x 104 J can be written as: 120 kJ.
1632 W can be written as 1.632 kW.
(xiv) If the magnitude of the number is less than unity, the decimal sign should
preferably be preceded by zero, e.g. .072 should be written as 0.072.
(xv) The SI prefixed are not to be used with 0C or K.

1.5 CONVERSION FACTORS

Appendix 1 lists the conversion factors in a direct usable form for conversion
from one system of units to another system of unit.

References

1. The International System of Units (SI), National Institute of Standards and Tech-
nology (NIST) Publication No. 330, USA, 1991.
2. ISO 1000 : 1992/Amd. 1 : 1998 (E), SI Units and Recomendations for the Use of
their Multiples and Certain other Units (Amendment I), International Organization
for Standards, Switzerland.
3. Mills. I., T. Cvitas, K. Homann, N. Kallary and K. Kuchitsu, Quantities, Units and
Process Engineering Channel

Symbols in Physical Chemistry, 2nd Ed., IUPAC Chemical Data Series, Blackwell
Science Ltd., UK, 1993.
4. Bhatt, B. I. and S. M. Vora, Stoic biometry, 4lh Ed., Tata McGraw-Hill Publishing
Co. Ltd., New Delhi, 2004.
@ProcessEng
 Chapter

Stoichiometry

2.1 INTRODUCTION

Stoichiometry is a branch of chemistry which deals with combining the propor-

tions of the elements or compounds involved in chemical reactions. It is based on
three concepts; conservation of mass, the relative masses of atoms and definition
of a mole. While the last two concepts were introduced in Chapter 1, the law of
conservation of mass is dealt in this chapter.
In any chemical reaction or in a unit operation, exchange of thermal energy
also takes place. Therefore, heat balance is also important in stoichiometric cal-
culations. Similar to mass balance, heat balance calculations are based on the law
of conservation of energy (the first law of thermodynamics).

2.2 BASIC CHEMICAL CALCULATIONS

Before attempting mass and energy balance problems, knowledge of basic prin-
ciples of chemical engineering calculations is necessary. A brief review of these
calculations is presented as follows.

2.2.1 Atomic Mass and Molar Mass

Elements are basic entities which are combined (or reacted) to form a compound.
As seen in Chapter 1, relative atomic masses for each element are presented on a
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unified scale which is known as Atomic Masses (Weights) of Elements'.

For chemical compounds, a mole is defined as the amount of substance equal
to its formula weight. Molar mass (M) is thus the total mass of elements, con-
tained in the compound. Thus it is easy to calculate molar mass of a compound,
knowing its chemical formula.

Example 2.1
@ProcessEng

Calculate molar mass of:

(a) Sulphurous chloride (SOCy and
(b) 2,4,6 - trinitrophenol (also known as picric acid)
 Stoichiometry

Solution:
(a) Molar mass of SOCIj = Atomic mass of sulphur + Atomic mass of oxygen + 2
x Atomic mass of chlorine
= 32.065 + 15.99 94 + (2 x 35.453)
= 118.9704 (exact) kg/kmol
With rounded off values of atomic masses, molar mass of SOCU = 32 + 16 + 2
x 35.5 = 119
(b) Chemical formula of picric acid = QHh (NOj^OH
Molar mass of picric acid = 6 x 12.0107 + 3 x 1.007 94 + 3 x 14.0067 + 7
x 15.9994
= 72.0642 + 3.023 82 + 42.0201 + 111.9958
= 229.103 92 (exact) kg/kmol
~ 229 (rounded off value)

In this book, rounded off values of atomic masses will be used for convenience.

2.2.2 Mole

In Chapter 1, mole is defined as a base unit in SI. It can be further defined as the
amount of substance containing 6.022 1367 x 10 molecules (also known as
Avogadro's number, NA). In simple terms, number of moles can be found by
dividing mass of the compound by its molar mass.

Example 2.2
Convert following into moles.
(a) 1000 kg boron trichloride (BCI3)
(b) 1500 kg phenol (C6H5OH)
Solution:
(a) Molar mass of BCI3 = 11 + 3 x 35.5 = 117.5 kg/kmol

1000 kg BCU3 = = 8.5106 kmol

117.5
(b) Molar mass of C6H5OH = 6x12 + 6x1 + 16
= 94 kg/kmol

1500 kg
0 C.HcOH = = 15.9574 kmol
" 3 94
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2.2.3 Mass Fraction and Mole Fraction

In a mixture, mass fractions (w) or mole fractions (x, y) are expressed to represent
its composition. Mass fraction is the ratio of the mass of a particular substance
divided by total mass of the substance. Similarly, mole fraction is the ratio of the
moles of a particular substance divided by total moles of all the substances. One
@ProcessEng

can be calculated knowing the other.

Example 2.3
Aqueous calcium chloride brine contains 35% CaC^ by mass. Convert the same in
mole %.
 Introduction to Process Engineering and Design

Solution:
Basis : 100 kg brine

Table 2.1 Composition of Brine

Component Mass Molar mass Moles Mole %

kg kg/kmol kmol C*,.)
CaCl2 35 III 0.3153 8.03
H20 65 18 3.6111 91.97

Total 100 3.9264 100.00

Average molar mass (M) of the solution = = 25.47 kg/kmol

3.9264

Example 2.4
Feed gas to ammonia synthesis loop has molar composition 24.75% N2, 74.25% H2,
0.7% CH4 and 0.3% Ar. Calculate its mass composition, average molar mass and spe-
cific gravity (with respect to air).
Solution:
Basis : 100 kmol feed gas

Table 2.2 Composition of Feed Gas to Ammonia Synthesis Loop

Component kmol Molar mass Mass Mass %

kg/kmol kg

N2 24.75 28 693.0 80.14

H2 74.25 2 148.5 17.17
ch4 0.70 16 11.2 1.30
Ar 0.30 40 12.0 1.39

Total 100.00 864.7 100.00

Average molar mass (M) of feed gas = = 8.647 kg/kmol

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Similarly, average molar mass of air can be calculated to be 28.968 (rounded off value
to be 29).

8 647
Specific gravity of feed gas = " = 0.2985
28.968

while mass fractions are useful in establishing material balances, mole fractions
@ProcessEng

are logical expressions in chemical reactions.

2.2.4 Density and Specific Gravity

Density of a compound in any state (solid, liquid or gas) is expressed as the ratio
of mass per unit volume. It is normally expressed in g/cnr, kg/L or kg/nr.
 Stoichiometry

Density of iron is 7.75 g/cm3 at 20oC while that of 24% BaCl2 solution at 40oC is
1.243 g/cm3.
Specific gravity of a liquid or solid is a dimensionless number and it is defined
as the ratio of density of solid or liquid at a given temperature to the density of
water at 40C (which is nearly equal to 1.000 g/cm ). For liquids, specific gravities
are often expressed in terms of certain hydrometers. Among these, Twaddell
(0Tw) and 0Baume ^Be') scales are well known. In petroleum industry, hydrom-
eter scale called 0API is used which is very useful in finding certain properties
like molar mass, viscosity, heating value, etc. Specific gravity of 24% aqueous
BaC^ solution at 40oC is 48.6 0Tw. Strength of certain important inorganic solu-
tions such as that of caustic soda solutions, sulphuric acid solutions, etc. are
tabulated on 0Tw or 0Be scale as hydrometers are convenient for use in industry.
Specific gravity of a gas is the parameter which indicates the heaviness of a
gas as compared to that of air. One definition is the ratio of molar mass of gas to
the molar mass of air. In Example 2.4, specific gravity of feed gas to ammonia
synthesis loop is determined to be 0.2985, indicating that it is much lighter than
air (both at same operating conditions).
Another definition of specific gravity of a gas is the ratio of the density of the
gas at given conditions of pressure and temperature to the density of air at refer-
ence conditions. Although this is a more logical expression, molar mass ratio is
chosen in this book to express heaviness of a gas as compared to the air.

2.2.5 Vapour Pressure and Boiling Point of Liquid

When a liquid is heated, it gets converted to vapour at a given temperature and

pressure. For a pure liquid, since degree of freedom is one, it boils at a constant
temperature for a given pressure. Conversely, for a pure liquid at a given tem-
perature, its equilibrium pressure is fixed which is known as vapour pressure.
This implies that when both phases exist in equilibrium, there is only one definite
pressure (called vapour pressure) at a given temperature for a single component.
Boiling point of a pure liquid at standard atmospheric pressure (1 atm or 101.325
kPa) is called normal boiling point (NBP). At 1 atm, water boils at 100oC, ethyl
alcohol boils at 78.40C, methylene chloride boils at 40.1oC and refrigerant 134a
(tetrafluoroethane) boils at -26.10C. All are called normal boiling points.
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Relationship of vapour pressure with its saturation temperature is expressed

either empirically or in tabulated form. Variety of equations are known for calcu-
lating vapour pressure of a liquid. Among these, Antoine equation is well known
and is expressed as follows:

\ogpv = A — (2.1)
(T + C)
@ProcessEng

where pv is vapour pressure at temperature T (in K) while A, B and C are con-

stants. Ref. 1 lists values of A, B and C for several liquids. Validity of equations
for a given liquid is limited in a definite temperature range. Number of other
equations are reported in literature for accurate prediction of vapour pressure.
 Introduction to Process Engineering and Design

Some of the fluids are extensively used in industry over a wide range of pres-
sure and temperature. Their applications could vary from heating, cooling or
processing. Steam and certain vapour phase heating fluids are used for heating.
Similarly a variety of refrigerants are used for cooling. n-Hexane is used for
extraction of oil from seeds. Nitrogen, oxygen etc. are also used as feed in
various chemical reactions. Carbon dioxide, water, propane and butanes are used
in their supercritical states for extraction and for carrying out certain chemical
reactions. Thus, thermo-physical properties of all such fluids are required at dif-
ferent pressures and temperatures. For this reason, properties of these fluids are
available in tabular form. These tables list temperature and its corresponding
vapour pressure as one properly. For example, steam tables (Ref. 2) are widely
used in industry. Data, read from the table, permit quick calculations.
Several other properties of liquids and solutions are of importance in chemical
engineering calculations. References 1 and 3 may be referred for the disussions
on these properties.

2.2.6 Gases

Gaseous state of a pure component is defined by its pressure and temperature.

However, when a mixture of gases is present, its composition is also required to
be specified. In a conventional practice, mole % composition of a gaseous mix-
ture is specified (as seen in Example 2.4).
Gases behave as ideal in a definite range of pressure and temperature such that
they obey the well known ideal gas law.
pV=RT (2.2)
where, p = absolute pressure of the gas, kPa
V = volume occupied by the gas, m3
R = Universal Gas Constant
= 8.314 51 J/(mol ■ K) or m3 • kPa/(kmol • K)
T = absolute temperature of the gas, K
When p is chosen as one standard atmosphere (101.325 kPa) and T is chosen
as 273.15 K (i.e. 0oC), these are called normal conditions (i.e. NTP).
Molar volume at NTP of an ideal gas is 22.4136 m3/kmol.
Conversely an ideal gas is one which follows Eq. (2.2). Most gases under
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ordinary circumstances (such as ambient conditions) obey ideal gas law. How-
ever, real gases deviate significantly at high pressures and high temperatures.
Real gas behaviours are described by equations of state (also called p-V-T rela-
tionship). Reference 4 may be referred for more information on various equa-
tions of state. p-V-T relations can be represented on phase diagrams, p-t dia-
grams for water and carbon dioxide are given in Fig. 7.22 and Fig. 7.23.
@ProcessEng

Critical conditions of a gas are those beyond which a gas cannot be liquefied.
These conditions are defined by critical temperature, critical pressure and critical
volume. By definition, critical temperature is the maximum temperature at which
a gas can be liquefied. The critical pressure is the saturation (vapour) pressure
corresponding to the critical temperature. The volume, occupied by the gas at
critical point is the critical volume. At the critical point, densities (or specific
 Stoichiometry

volumes) of gas and liquid (in equilibrium) are equal. Reference 1 lists the criti-
cal properties of number of compounds.
Physical state of a fluid above its critical conditions is known as supercritical
state. In Chapter 7, extraction in supercritical fluids is discussed. Table 7.7 lists
the critical properties of commonly used supercritical fluids.
When a mixture of gases is handled, its composition is specified in mole %.
For an ideal gas mixture,
mole % = volume % = pressure %
Partial pressure (or pure component pressure) of a component in the gas mix-
ture is defined as total pressure of the system multiplied by the mole fraction of
the component.
Pi = p- 37 (2-3)
where, /?, = partial pressure, kPa
p = total pressure, kPa
yi = mole fraction of the component in vapour phase
For an ideal liquid-vapour mixture, equilibrium is represented by Raoult's
law,
Pi = p- yi = Pvi • *,• (2-4)
where, pvj = vapour pressure of the component at a given temperature, kPa
xi = mole fraction of the component in liquid phase
Conversely an ideal liquid mixture is one which follows Raoult's law. Non-
ideal behaviour of the liquid mixture is expressed in different ways for which a
standard text book on thermodynamics may be referred (Ref. 4).
For certain liquid mixtures at a definite composition, liquid and vapour com-
positions are same at a given pressure. Composition of such a mixture is known
as azeolropic composition. Ethyl alcohol-water, toluene-water and many
multicomponent mixtures exhibit this property which is advantageously used in
the industry to remove water from organic reaction mass.

2.2.7 Material Balances

A process represents a series of actions or operations or treatments that result in

an end product. In chemical engineering, physical and/or chemical changes take
place during the operations and the material flows and its inventory in a system
Process Engineering Channel

are quantified during these operations which is known as material balance.

A system can be defined as the body or assemblage in which the process is set
out for analysis. When a system is isolated from the surroundings, it is called a
batch system. In other words, there is no transfer of materials from a batch during
the lime interval of interest. Contrary to this, in open system, material is trans-
ferred across the boundaries; i.e. from and to the surroundings. Thus it is impor-
@ProcessEng

tant to define the system being analyzed.

Having defined the system, it is important to fix a basis; e.g. 100 kg feed, 100
kg reactanl A, 100 kmol gas mixture, 1000 L liquid, etc. All computations are
performed considering this basis. In a prolonged analysis of the system, it may
become necessary to shift bases but interrelation of all the bases should be clear.
 Introduction to Process Engineering and Design

It is thus clear that material balance is a quantitative expression of law of

conservation of matter. It can be expressed as
Input = Output + Accumulation (2.5)
Equation (2.5) is always true for elements but often not true for compounds
participating in chemical reactions. Because of its fundamental nature, material
balance is one of the most useful tools in system analysis and therefore in process
design.

2.2.7.1 Material Balances Involving No Chemical Reactions

In most unit operatios, reactions do not take place. Material balances of such
systems are worked out by making balances of a tie material or inert material.
When two or more compounds in the system are simultaneously affected, mate-
rial balance equations are solved by satisfying simultaneous equations.

Example 2.5
Soyabean seeds are batch extracted with n-hexane. Flaked seeds containing 19% oil,
69% solids and 12% moisture (by mass) are fed to the batch extractor. At the end of the
extraction process, deoiled cake (DOC) is found to contain 1% oil, 88% solids and rest
moisture (by mass). Find the percentage recovery of oil.
Solution:
Basis : 100 kg soybean seeds
Since solids do not take part in the extraction process, its balance can be made.
Solids in the feed = 100 x 0.69 = 69 kg
DOC contains 88% solids.

Quantity of DOC = — = 78.41 kg

0.88
Oil in seeds = 100 x 0.19 = 19 kg
Oil in DOC = 78.41 x 0.01 = 0.784 kg

(19-0.784)
Oil recovery = — x 100

= 95.87%

Example 2.6
Process Engineering Channel

n-Butanol - water forms an azeotrope having composition of 57.5% n-butanol (by mass)
at 930C and 1 atm. When azeotropic vapour is condensed, and cooled to 20oC, the
mixture separates in two layers. Top layer and bottom layer consist of 79.93% and 7.81%
n-butanol, respectively (by mass) at 20oC. Calculate the proportions of top and bottom
layers.
Solution:
@ProcessEng

Basis : 100 kg azeotropic vapour to condenser.

n-Butanol in vapours = 57.5 kg
Water in vapours = 100 - 57.5 = 42.5 kg
In the liquid phase, the mixture separates in two layers. Since both components are
affected, simultaneous equations need to be solved.
Let m, kg be top layer and m2 kg be the bottom layer.
 Stoichiometry

Overall balance : m, + W2 = 100

=
/j-butanol balance : 0.7993 m, + 0.0781
Solving the equations, ml = 68.9 kg, = 31.1 kg
Solving simultaneous equations for a binary system could be easily done manually.
However, when many components are present, use of a mathematical software such as
Mathcad® will be advantageous.

2.2.7.2 Material Balances Involving Chemical Reactions

Material balance calculations of processes involving chemical reactions follow

the same law of conservation of mass. However, moles are important rather than
mass in chemical reactions. For material balance calculations, conversion and
yield are required.
Conversion is defined as the fraction of the reactant in the feed which is con-
verted to product(s). Conversion is normally defined on the basis of the limiting
reactant which is present in the smallest stoichiometric amount. Yield is defined
by the following equation.

moles of desired product x stoichiometric factor

Yield = (2.6)
moles of specific reactant consumed

where, stoichiometric factor = stoichiometric requirement of the specific reac-

tant (in moles) per mole of the desired product
Selectivity is the ratio of amount of limiting reactant that reacts to give the
desired product to the amount that reacts to give undesirable product(s).
One more term used in reaction engineering is the excess of reactant which is
defined as the reactant present in excess of stoichiometric requirement of the
limiting reactant on mole basis.
While conversion is related to the degree of completion of reaction, yield and
selectivity are related to the degree to which the desired reaction proceeds.
Study of oxidation reaction to produce nitrogen monoxide can be useful to
understand various terms.
Following are the chief competing reactions taking place in the reactor in a
nitric acid plant
4 NH3 + 5 02 —> 4 NO +6 H20 (a)
Process Engineering Channel

4 NH3 + 3 02 2 N2 +6 H20 (b)

4 NH3 + 4 02 -> 2 N20 + 6 H20 (c)
Above reactions are carried out over a precious metal catalyst at high
temperature. Aim is to maximize production of NO. Ammonia and oxygen (in
the form of air) are the reactants. At the exit of the reactor, ammonia is completely
consumed and hence it is the limiting reactant. Oxygen is fed in excess over the
@ProcessEng

stoichiometric requirement (5/4 times ammonia feed rate) and is termed as the
excess reactant. In this case conversion is 100% based on ammonia. Stoichiometric
factor for reaction (1) is one, i.e. 1 mole NO is formed per mole of ammonia.
Typical yield of NO is found to be 0.93 - 0.98 depending on operating temperature
and catalyst activity. Take for example, yields of NO, N2 and N2O as 0.95, 0.02
and 0.03, respectively.
 Introduction to Process Engineering and Design

NH, consumed for desired product = 0.95 kmol

NH3 consumed for undesired products = 0.02 x 2 + 0.03 x 2
= 0.1 kmol
Selectivity of the catalyst = 0.95/0.1 = 9.5
Combustion of a fuel is another oxidation reaction in which oxygen (i.e. air) is
fed in excess to achieve complete combustion. Fuel is thus the limiting reactant.
Oxygen is supplied in excess over the stoichiometric requirement in the form of
air. Knowing the flue gas and fuel analyses, it is possible to calculate the excess
air.

Example 2.7
Flue gas mixture from a waste incinerator is analysed and found to contain 12% COj,
5.5% O2 and rest N2 (by mole) on dry basis. Assuming complete combustion, calculate
the excess air and C:H mass ratio in fuel.
Solution:
Basis : 100 kmol dry flue gases

Table 2.3 Flue Gas Analysis on Dry Basis

Component kmol O2 accounted

kmol
C02 12 12
02 5.5 5.5
n2 82.5 —

Total 100.0 17.5

Assume negligible nitrogen in the fuel (i.e. waste).

0-, supplied in the form of air = — x 82.5 = 21.93 kmol

79
O2 consumed in reaction with hydrogen = 21.93 - 17.5
= 4.43 kmol
Hydrogen reacted = 4.43 x 2
= 8.86 kmol
Carbon in waste =12x12 =144 kg
Process Engineering Channel

Hydrogen in waste = 8.86 x 2 = 17.72 kg

144
C:H ratio in waste =
17.72
= 8.13:1 by mass
Total oxygen consumed for combustion
= 12 + 4.43
= 16.43 kmol
@ProcessEng

Excess oxygen or air = (5.5/16.43) 100

= 33.48%

2.2.7.3 Recycling and Bypassing Operations

Recycle stream is a process stream from exit or downstream from a unit back to
the inlet or upstream of the same unit. Nature is a classical example in which
nitrogen and oxygen are recycled. Animals inhale oxgen and exhale carbon
 Stoichiometry

dioxide. The latter is used by plants for manufacture of food in presence of sun
light. In this photosynthesis reaction, oxygen is released. In unit operations and
in chemical reactions, recycling operations are performed for a variety of reasons.
One of the chief reasons of recycling is to maximize the utilization of reactant(s)
in reaction. Hydrogen is used in excess in many reactions. After the reaction,
excess hydrogen is recycled from the separation unit back to the reaction unit.
For recovery of volatile organic compounds (VOC) from vent gases, carbon
adsorption units are commonly employed. Nitrogen is used for regeneration of
the carbon bed from which VOC is separated. VOC laden nitrogen is recycled.
Other reasons for recycle are utilization of heat from the outgoing stream, to
improve the performance of an equipment, to improve selectivity of a product, to
improve safety of the process, to minimize waste generation, etc.
Chemical engineers are familiar with reflux in a distillation column. It is basi-
cally a recycle stream to maintain specific quality of the top product. In Chapter
8, number of examples are given for calculating reflux ratio which represent
material balance in an unit operation.
In a loop reactor fraction of product stream (after cooling) is recycled back to
the reactor to control the exhothermicity of reaction.

2.3 ENERGY BALANCES

It is a known that most physical and chemical changes are accompanied by enthalpy
changes. It is therefore necessary to study the enthalpy balances.
Energy exists in different forms such as potential energy, kinetic energy, ther-
mal energy, electrical energy, etc. In SI units, the unit of all types of energy is
Joule (represented as J). Conversion of one form of energy into another is feasi-
ble. However, total energy of the universe is constant.
In this section, discussions will be limited to thermal energy and the terms
energy, enthaply and heat are essentially used for thermal energy. While enthalpy
of a substance is associated with its state (i.e. pressure and temperature), the term
heat is used for the enthalpy in transit. In physical and chemical changes, flow
rate of heat (in W in SI units) is of interest to process engineers.

2.3.1 Sensible Heat Changes

Process Engineering Channel

Sensible heat changes in solid, liquid or gas means change in temperature of the
substance. Increase in temperature is termed as heating while a decrease is termed
as cooling. For evaluation of the heat change, mass, temperatures and heat capac-
ity are required.
For any substance, heat capacity is defined as the heat required to effect the
temperature change by 10C of 1 kg substance. Thus, units of heat capacity are kJ/
@ProcessEng

(kg • 0C). If the heat capacity of one mole substance is specified, it is known as
molar heat capacity and its units are kJ/(kmol • 0C).
For gases, heat capacity depends on the route, followed for changing the tem-
perature. One route is known as constant pressure path while another route is
constant volume path. Majority of the processes follow constant pressure route
and the heat capacity for the route is denoted by Cmpi and has units kJ/(kmol • 0C).
 Introduction to Process Engineering and Design

This quantity is dependent on pressure and temperature. At 1 atm pressure, it is

denoted by symbol C0mp. A number of equations are developed, offering a rela-
tionship of C0mp with temperature at 101.325 kPa. Among these, polynomial forms
are used extensively.
C0mp = a + hT+cT2 (2.7)
0 2 3
or C mp = a + bT + cT + dT (2.8)
Where a, b, c and d are constants (separate values for both equations) and T is
temperature in K.
Values of C°np, derived from the equations, are accurate at 1 atm but they can
be safely used for sub-atmospheric pressure and upto about 10 bar a. Correla-
tions, graph and tables are available in literature for prediction of Cmp at high
pressures (Ref. 1, 3, 4).
For mixture of ideal gases, sensible heat changes are calculated by calculating
heat capacity of the mixture, using the following equation.
0
C C0mpi
^ mp mix = T yvi • ^
where, C0mp mix = heat capacity of gas mixture, kJ/(kmol • 0C)
y, = mole fraction of /th component
C mpi = heat capacity of /th component of gas mixture, kJ/(kmol • 0C)
0

This equation is strictly valid for an ideal gas mixture but can be used for most
practical purpose upto moderate pressures.
In case of liquids, heat capacities at constant pressure and at constant volume
are nearly equal. Also variation of the heat capacity with pressure is insignificant
for most liquids. Symbol for heat capacity of liquid is Q. Polynomial equations
are also developed for correlating C, with T. For aqueous solutions, liquid mix-
tures, petroleum fluids, etc. graphical and tabulated data are available in litera-
ture. Heat capacity of an immiscible liquid mixture is given by

* Q (2-9)
0
where, C/mix = heat capacity of liquid mixture, kJ/(kmol • C)
Xj = mass fraction of /th component
Cn = heat capacity of /th component of liquid mixture, kJ/(kmol • 0C)
Heat capacity of solids (Cv) are lower than that of liquids and increase with the
increase in the temperature. However, variation of Cs with respect to T is gener-
Process Engineering Channel

ally insignificant.

2.3.2 Heat Changes During Phase Change

A study of p-t diagram (Fig. 7.22 and Fig. 7.23) reveals interesting facts about
phase changes. Above triple point, there are two phase change. When a solid is
melted above its freezing point, latent enthalpy (or heat) of fusion is to be sup-
@ProcessEng

plied. Water melts at 0.010C at standard atmospheric pressure (101.325 kPa).

Latent enthalpy of fusion at this temperature is 339.4 kJ/kg. In general, melting
point of a pure fluid increases with increase in pressure while latent enthalpy of
fusion decreases.
When heat is supplied to convert liquid to vapour at a constant temperature, it
is called that latent enthalpy (heat) of vapourization. Water evaporates at 100oC
 Stoichiometry 21

at 101.325 kPa when heat equivalent to 2256.9 kJ/kg is supplied. Saturation tem-
perature of a pure fluid increases with increase in pressure while latent enthalpy
of vaporization decreases and becomes zero at critical point.
Below triple point, a fluid sublimes from solid to vapour. Heat, supplied to
change the solid phase to vapour phase of a pure substance, is called the latent
enthalpy (heat) of sublimation. Sublimation temperature and latent enthalpy of
sublimation decreases with decrease in pressure below triple point. Carbon diox-
ide sublimes at -78.460C at 101.325 kPa and latent heat of sublimation is 571.0
kJ/kg. At triple point, latent heat of sublimation can be considered a total of
latent heat of fusion and latent heat of vaporization. Triple point of carbon diox-
ide is -56.560C at 5.18 bar. At this temperature, latent heat of fusion is 197.22 kJ/
kg and latent heat of vaporization is 350.38 kJ/kg. Thus latent heat of sublima-
tion at this temperature is 547.60 kJ/kg.
Above critical point, again sublimation of solid to vapour is experienced as
there is no liquid phase. Critical temperature and critical pressure of water are
374.150C and 221.2 bar, respectively. Water sublimes at -50C at 600 bar and
latent heat of sublimation is 319.92 kJ/kg at this temperature.
Various correlations are available in literature for prediction of latent heat of
fusion and vaporization. However, latent heat of vaporization is most useful to a
process engineer. Tables of thermodynamic properties (Ref. 2) are available in
literature for large numer of compounds. At standard atmospheric pressure, fol-
lowing equation is found to give latent heat of vaporization within 5% accuracy.

5 1.092 (In n.-5.6182)

= — (2.10)
RTB 0.930 - TBr
where, A = latent heat of vaporization at TB, kJ/kmol
pc = critical pressure, kPa
Tb = normal boiling point, K
TBr = reduced temperature at TB = TB/TC
R = 8.314 51 kJ/(kmol • K)
Knowing latent heat of vaporization at one temperature, it can be calculated at
another temperature, using the following Watson equation.

A. Tc-Ti
Process Engineering Channel

(2.11)
/U Tc-T2
where. A, and ^ refer to latent heat of vaporization at temperatures T] and
(in K) respectively, Tc is critical temperature (in K) and n is characteristic con-
stant, having a value of 0.38. Watson equation is simple and reliable in most
cases.
For heat changes calculations during phase change, latent heat of appropriate
@ProcessEng

phase change is to be taken into account.

2.4 ENTHALPY CHANGES ACCOMPANYING

CHEMICAL REACTIONS

When any chemcial reaction takes place, enthalpy changes are encountered. This
is known as heat of reaction. For combustion reactions, it is termed as heat of
 Introduction to Process Engineering and Design

combustion. For calculation of heat of reaction, heal of formation data are

required.
Standard heat of formation is defined as the isothermal enthalpy change in a
synthesis reaction from the elements in their standard states. Standard heat of
formation, denoted by A//° of large number of compounds, is available in litera-
ture1 in tabular form. Standard states of compounds are pure crystalline solid at
250C (298.15 K) and for pure liquid and pure gas are 1 bar a and 250C (298.15
K). Since combustion reactions are easy for experiments, standard heat of
combustion (A//°.) data so obtained are used to calculate the standard heat of
formation.
Standard heat of formation data are obtained for isothermal conditions. It var-
ies with the temperature. Empirical relation of A/fy with 7" is a polynominal equa-
tion, similar to that for heat capacity of gas [Eq. (2.7) or Eq. (2.8)1.
Consider a chemical reaction between A and B to produce C and D. Stoichio-
melric relation can be written as
nA + nB = nc + nD
where, n(- = number of moles of ith component. Standard heat of reaction
(AHr) for the above reaction can be calculated by the following equation.
AH°r = 1 (rij ■ A7/y()products - I (ni ■ AH°p) Reactants

0
where, AH fi = Standard heat of formation of /th component
Since AHJi will be at 250C, AHB will be also at 250C. However, if AH^ at some
another temperature is taken (but all at one specific temperature), AHR will corre-
spond to that temperature.
If heat of reaction is positive, the reaction is said to be endolhermic while if
the heat of reaction is negative, the reaction is termed exothermic.

Example 2.8
Standard heat of formation of liquid oleic acid (C^Hj^) is - 802.9 kJ/mol at 250C.
Calculate its gross calorific value at 250C.
Solution:
Basis : 1 mole liquid oleic acid
Gross calorific value or higher heating value is the heat liberated when a mole of the
combustible compound is burnt with stoichiometric amount of pure oxygen at 250C,
Process Engineering Channel

product carbon dioxide is in gaseous form while product water is in liquid form. Com-
bustion reaction of oleic acid can be written as
^-'18^34^2(0 +25.5 02(g) = 18 C02(g) + 17 ^O,,)
AHp -802.9 0 18 x (-393.51) 17 x (-285.83)
Standard heat of formation data for CO2 and H2O are taken from Ref. 1.
AH0r< = 18 (-393.51) + 17 (-285.83) - (-802.9)
@ProcessEng

= -11 139.4 kJ/mol of liquid oleic acid

Literature reports AHR at 20oC for liquid oleic acid as - 11 154 kJ/mol.

Example 2.9
In the manufacture of nitric acid, ammonia is oxidized to nitric oxide on a Pt/Rh gauge
(as catalyst) as per the following reactions.
 Stoichiometry

4NH3(g) + 5 02(g) = 4N0(g) + 6H20(g) (a)

4 NH3(g) + 3 02(g) = 2 N2(g) + 6 H20(g) (b)
4 NH3(g) + 4 02(g) = 2 N20(g) + 6 H20(g) (c)
Liquid ammonia at atmospheric pressure is pumped to 9.0 bar a. It is first vaporized
with cooling water and subsequently superheated to desired temperature using low pres-
sure saturated steam at 5 bar a. Oxygen in the form of air is supplied. Air is compressed
to 9.3 bar a and 130oC in a two-stage compressor, driven by a steam driven turbine.
Further it is heated to 260oC with the reactor exit stream. Superheated ammonia at the
rate of 3266 NnrVh and hot air at the rate of 29 394 NnvVh are fed to the reactor. Ambi-
ent air has 0.016 kg moisture/kg dry air. In the reactor, ammonia is completely con-
sumed. Yields of NO, N2 and N20 are 95%, 2% and 3%, based on ammonia conversion.
Reactor exit gas stream temperature is observed to be 9150C at 7.5 bar g. Carry out the
material and energy balances of the reactor system and preheating equipments.
Solution:
Basis :
Ammonia flow rate to reactor, qam = 3266 Nm Vh
Molar flow rate of ammonia, qam = 3266/22.4136
= 145.71 kmol/h
Volumetric flow rate of moist air, qa = 29 394 NnrVh
Molar flow rate of moist air, qa = 29 394/22.4136
= 1311.44 kmol/h
Assume dry air molar composition to be 21% 02, 1% Ar and 78% N2.
Average molar mass of dry air =0.21 x 31.9988 + 0.01 x 39.948 + 0.78 x 28.0134
= 28.9697
Moisture in dry air = 0.016 kg/kg dry air
= 0.016x28.9697/18.0153
= 0.0257 kmol/kmol dry air
Moist air = 1.0257 kmol/kmol dry air
Moisture, entering with air = 1311.44 x 0.0257/1.0257
= 32.86 kmol/h
Dry air flow rate to reactor = 1311.44 - 32.86
= 1278.58 kmol/h
02 supply to reactor = 1278.58 x 0.21 = 268.50 kmol/h
Argon supply to reactor = 1278.58 x 0.01 = 12.79 kmol/h
Process Engineering Channel

N2 supply to reactor = 1278.58 - 268.50 - 12.79

= 997.29 kmol/h

Table 2.4 Thermodynamic Data1

Component State Molar AHj- Heat Capacity Equation Constants

mass kJ/inol a h x 10- cx 10° dx 109
@ProcessEng

kg/kmol
NH3 gas 17.0305 -45.94 25.6503 33.4806 0.3518 -3.0832
o2 gas 31.9988 0 26.0257 11.7551 -2.3426 -0.5623
N2 gas 28.0134 0 29.5909 -5.141 13.1829 -4.968
Ar gas 39.948 0 20.7723 — — —
(Contd.)
 Introduction to Process Engineering and Design

Table 2.4 (Conld.)

Component State Molar AH} Heat Capacity Equation Constants

mass kJ/mol bx KT c x 10 dx 10J
kg/kmol
NO gas 30.0061 90.25 29.4867 -2.0524 11.3379 -4.8195
N20 gas 44.0128 82.05 23.2082 63.6695 -42.3402 10.4061
no2 gas 46.0055 33.18 23.5804 53.5944 -31.4901 6.5394
H->0 gas 18.0153 -241.82 32.4921 0.0796 13.2107 -4.5474
h2o liquid 18.0153 -285.83
HNO, liquid 63.0128 -174.10

Source of data: Ref. 1

Conversion = 100%
Yield of NO = 95%
NH3 converted to NO= 145.71 x 0.95
= 138.42 kmol/h
NO produced = 138.42 kmol/h
NH3 converted Nj = 145.71 x 0.02
= 2.91 kmol/h
N2 produced = 2.91 x 2/4
= 1.457 kmol/h
NH3 converted to NjO = 145.71 - 138.42-2.91
= 4.38 kmol/h
NjO produced = 4.38 x 2/4
= 2.19 kmol/h
Total O2 consumed = 138.42 (5/4) + 2.91 (3/4) + 4.38 (4/4)
= 173.025 + 2.183 + 4.38
= 179.588 kmol/h
Oj in reactor exit stream = 268.50- 179.588
= 88.912 kmol/h
Total HjO produced = 145.71 x 6/4
= 218.565 kmol/h
Total FRO in reactor exit stream = 218.565 + 32.86
= 251.425 kmol/h
Total N, in reactor exit stream = 1.457 + 997.29
Process Engineering Channel

= 998.747 kmol/h

Table 2.5 Reactor Ingoing Stream

Component kmol/h Mole % kg/h Heat Capacity Equation Constants

>h (wet) m, 'h ■ ai «,• ■ bi «,■ • c,- «/' d
i
3 6
x 10 x 10 x 109
@ProcessEng

NH3 145.71 10.00 2481.51 3737.5 4878.5 51.3 -449.3

N2 997.29 68.44 27 937.75 29 510.7 -5127.1 13 147.2 -4954.5
O2 268.50 18.43 8591.68 6987.9 3156.2 -629.0 -151.0
Ar 12.79 0.87 510.93 265.7 - — -
H20 32.86 2.26 591.98 1067.7 2.6 434.1 -149.4
Total 1457.15 100.00 40 113.85 41 569.5 2910.2 13 003.6 -5704.2
 Stoichiometry

Average molar mass of reactor ingoing stream

= 40 113.85//1457.15 = 27.53 kg/kmol

Table 2.6 Reactor Exit Stream

Component kmol/h Mole % kg/h Heat Capacity Equation Constants

n
i (wet) m(. n
i ■ ai n
i ■ bi "/ • 0 x ni ■ id
3 6
x 10 x 10 x I09

N2 998.747 66.92 27 978.30 29 553.8 -5134.6 13 166.4 -4961.8

02 88.912 5.96 2845.08 2314.0 1045.2 -208.3 -50.0
Ar 12.790 0.85 510.93 265.7 — — -
NO 138.420 9.27 4153.44 4081.5 -284.1 1569.4 -667.1
N20 2.190 0.15 96.39 50.8 139.4 -92.7 22.8
h2o 251.425 16.85 4529.50 8169.3 20.0 3321.5 -1143.4
Total 1492.484 100.00 40 113.64 44 435.1 -4214.1 17 756.3 -6799.5

Average molar mass of reactor exit stream

= 40 113.64/1492.484 = 26.88 kg/kmol
It may be noted that mass flow rates of ingoing and outcoming streams are equal
which should be checked during every material balance calculations.
Energy Balance:
For carrying out energy balance calculations, reference (or base) temperature need to be
fixed. Since standard heat of formation data are based on 250C, selection of 25°C as the
reference temperature is logical.
r0 = 25 + 273.15 = 298.15 K
Reactor exit gas temperature is desired at 9150C.
75 = 915+ 273.15= 1188.15 K
Heat flow rate of reactor exit stream
1188.15
08= j (44435 1 -42141 x KC3 r+ 17 756-3 x 10-6 T2-6799.5 x 10-9 T3) AT
298.15
= 43 156 523 kJ/h = 11 987.92 kW
Standard Heats of Reaction:
For reaction (a):
Process Engineering Channel

m0R[ = [4 (90.25) + 6 (-241.82)] - [4 (-45.94) + 5(0)]

' = 361 - 1450.92 + 183.76
= -906.16 kJ/4 mol NH3 reacted
= -226.54 kJ/mol NH3 reacted (exothermic)
For reaction (b):
A//°, = [2(0) + 6 (-241.82)] - [4 (-45.94) + 3(0)]
2
=-1450.92 + 183.76
@ProcessEng

= -1267.16 kJ/4 mol NH, reacted

= -316.79 kJ/mol NH, reacted (exothermic)
For reaction (c):
A//^ = [2 (82.05) + 6 (-241.82)] - [4 (-45.94) + 4(0)]
1
= 164.1 - 1450.92+ 183.76
 Introduction to Process Engineering and Design

= -1103.06 kJ/4 mol NH, reacted

s -275.765 kJ/mol NH3 reacted (exothermic)
Total heat liberated during reaction,
07 = (226.54 x 138.42 + 316.79 x 2.91 + 275.765 x 4.38)) 1000
= 33 487 377 kJ/h = 9302.05 kW
Heat input to reactor (i.e. for the reactants' stream)
06 =43 156 523 -33 487 377
= 9 669 146 kJ/h
= 2685.87 kW
Let temperature of reactants' stream be TA.
Ta
06 = J (41 569.5 + 2910.2 x 10~3 7+ 13 003.6 x lO-6 T1 - 5704.2 x 10-9 T3) (XT
298.15
= 9 669 146 kJ/h = 2685.87 kW
Solving by trial and error or by Mathcad, T4 = 515.22 K or 242.07oC
Among the two reactants, air is introduced at 260oC or 533.15 K (T^).
Heat input of air,
533.15
05= J (37 832- 1968.3 x 10-3 r+ 12 952.3 x 10-6 r2-5254.9 x 10-9 r3)dr
298.15
= 91 42 364 kJ/h = 2539.55 kW
Heat input by superheated ammonia,
04 = 9 669 146 - 9 142 364
= 526 782 kJ/h = 146.33 kW
If temperature of superheated ammonia is T2,
?!
04= j (3737.5 + 4878.5 x 10-3 7+ 51.3 x lO-6 T2 -449.3 x KT9 T3) dT"
298.15
= 526 782
Solving by Mathcad,
T2 = 395.41 Kor 122.260C.
Ammonia is fed at - 33.330C (saturation temperature at 101.325 kPa) as liquid. As-
sume that in the evaporator, liquid ammonia is vaporized and heated at 9.0 bar a to its
Process Engineering Channel

saturation temperature of 21.50C with cooling water.

T] =21.5 + 273.15 = 294.65 K
From ammonia tables (Ref. 2)
Enthalpy of liquid ammonia, h = 49.08 kJ/kg
Enthalpy of vapour ammonia at 9 bar a and 21.50C, H] = 1480.78 kJ/kg
Note that the values of both the above enthalpies are based on reference temperature
of 0oC in ammonia tables which is different from original reference temperature of
@ProcessEng

250C. Neverthless, since difference in only two enthalpy values is required, it does not
matter.
Heat duty of ammonia evaporator,
0, = 145.71 x 17.0305 (1480.78-49.08)
= 3552 784 kJ/h
= 986.88 kW
 Stoichiometry

Cooling water at 320C is used to evaporate liquid ammonia. Assume a drop in eool-
ing water temperature by 50C.

3552784
Cooling water flow, mrw =
5 CW
5x4.1868
= 169 714 kg/h
= 169.7 m3/h
Enthalpy of ammonia gas at 9.0 bar a and 122.260C, ^ = '740.15 kJ/kg
Heat duty of superheater, <p2= 145.71 x 17.0305 (1740.15 - 1480.18)
= 643 630 kJ/h
= 178.79 kW
If heat capacity data (at 1 atm) for ammonia, are used for calculations of (fa,
395.41
= j (3737.5 + 4878.5 x lO"3 7+ 51.3 x lO"6 T2 - 449.3 x lO"9 73) d7
294.65
= 544 914 kJ/h
= 151.37 kW

(643 630-544 914)

Error = x 100
643 630
= 15.34% - significant
Error indicates justification of tabular data, particularly at high pressures.
Saturated steam at 5 bar a is used for superheating ammonia vapours from 21.50C to
122.260C.
Latent heat of vaporization of steam at 5 bar a, A = 2107.4 kJ/kg (Ref. 2)
Steam consumption in superheater,

643 630
m.. =
2107.4
= 305.4 kg/h
Heat duty of air preheater,
533.15
03= j (37 832 - 1968.3 xlO"3 7+ 12 952.3 xl0-6 72-5254.9 xio-9 73)d7
Process Engineering Channel

403.15
= 5 098 328 kJ/h = 1366.16 kW

2.5 HEAT CHANGES IN MIXING PROCESSES

When a solid or gas is dissolved in a solvent, heat change takes place. This is
known as heat of solution. Also when two liquids are mixed, a heat change takes
@ProcessEng

place which is termed as heat of mixing. These heat changes are measured at
constant temperature, say at 250C (298.15 K) and at standard atmospheric pres-
sure. Units of the heat changes are kJ/mol solute, kJ/kg solution, etc. depending
on user's convenience.
When solids like causitc soda, caustic potash, sodium carbonate, etc. are
dissolved in water, heat is evolved. Similarly when acids are mixed (a mixture of
 Introduction to Process Engineering and Design

HNO3 + H2SO4 + H2O), heat is released. Dissolution of ammonia or formalde-

hyde in water is exothermic. These heat changes should be considered while
making heat balance calculations.
Heat of mixing data are extensively covered in many handbooks. Heat of
formation data for large number of compounds and their solutions is published
by National Institute of Standards and Technology, USA which permits heat of
mixing calculations. Reference 1 may be consulted for more discussions on the
subject.
Following example will illustrate the method of calculations relating to heat
of mixing in gas-liquid system.

Example 2.10
Refer Example 2.9, reactor exit stream is cooled in various heat exchangers to 40oC and
introduced in an absorber alongwith the condensate (formed in the coolers), operating at
1.5 bar g. Secondary air at the rate of 8145 Nm Vh is also introduced at the bottom of the
absorber at 40oC which converts NO to NOj. Fresh demineralized water is introduced
from the top at 250C which scrubs NO2 to produce HNO3. Absorption of NO2 in water
is exothermic and therefore cooling coils are provided in the absorber. Tail gas, leaving
the absorber at 0.1 bar g and 5()0C, is found to contain 0.2% NO (on dry basis). Aqueous
58% acid (by mass) leaves absorber at 50oC from the bottom. Make material and energy
balance of the absorber. Find cooling water requirement for the absorption system as-
suming availability of cooling water at 320C and a rise of 50C.
Solution:
Basis : Same as that of Example 2.9
Pressure of gas at the inlet of absorber, = 1.5 bar g
= 251.325 kPa a
Vapour pressure of water at 40oC = 7.375 kPa (Table 6.8 of Ref. 1)

7.375(1492.484-251.425)
Moisture in ingoing gas mixture =
(251.325-7.375)
37.519 kmol/h at 40oC
675.92 kg/h
Liquid water, entering absorber = 251.425-37.519
213.906 kmol/h at 4()0C
Process Engineering Channel

3853.58 kg/h
Pressure of outgoing mixture = 0.1 bar g
111.325 kPa a
Vapour pressure of water at 50oC = 12.335 kPa (Table 6.8 of Ref. 1)

12-335
Water content of tail gas =
(111-325-12-335)
@ProcessEng

kmol
= 0.1246
kmol dry gas
Secondary air flow = 8145 NnrVh
Molar flow rate of wet air = 8145/22.4136
= 363.4 kmol/h
 Stoichiometry

363-4x0-0257
Moisture, entering with air
1-0257
9.11 kmol/h
Dry air flow rate 363.4-9.11
354.29 kmol/h
O2 entering the absorber 354.29x0.21
74.40 kmol/h
Argon entering the absorber 354.29x0.01
3.54 kmol/h
Nj entering the absorber 354.29 - 74.40 - 3.54
276.35 kmol/h

Table 2.7 Gas Stream Entering Absorber

Compo- kmol/h Mole % kg/h Heat Capacity Equation Constants

i ■ i «, • h, x 10 n, ■ Cj x 10 n, - 4 x 10
3 6 9
nent *«, (wet) thj n a

n2 1275.097 77.66 35 719.80 37 731.3 -6555.3 16 809.5 -6334.7

02 163.312 9.95 5225.79 4250.3 1919.7 -382.6 -91.8
Ar 16.330 0.99 652.35 339.2
NO 138.420 8.43 4153.44 4081.5 -284.1 1569.4 -667.1
N20 2.190 0.13 96.39 50.8 139.4 -92.7 22.8
H?0 46.629 2.84 840.04 1515.1 3.7 616.0 -212.0
Total 1641.978 100.00 46 687.81 47 968.2 -4776.6 18 519.61 -7282.8

46687.81
Average molar mass of gas mixture, entering absorber = = 28.43
S 6 5
' 1641.978
Reaction:
2NO(g)+1.5 02(g) + H20(Z) = 2 HN03(/)
Let x kmol/h NO is reacted by the above reaction.
O2 consumed = 1.5 xl2
= 0.75 x kmol/h
NO in tail gas = 138.42 - x kmol/h
Dry tail gas = 1641.978-x-0.75x-46.629
Process Engineering Channel

= 1595.349 - 1.5a- kmol/h

Tail gas contains 0.2% NO.
(138-42 - A)100
=0.2
1595-349-1-5A
a = 135.63 kmol/h
Dry tail gas = 1595.349 - 1.5 x 135.63
@ProcessEng

= 1391.904 kmol/h
Moisture in tail gas = 0.1246 x 1391.904
= 173.431 kmol/h
 Introduction to Process Engineering and Design

Table 2.8 Absorber Exit (Tail Gas) Stream

Compo- kmol/h Mole % kg/h Heat Capacity Equation Constants

nent n
i (dry) m, Ki ■ dj «, • h, x I03 tij ■ Cj x 106 «,■ • di x 109

N2 1275.097 93.90 35 719.80 37 731.3 -6555.3 16 809.5 -6334.7

o2 61.590 4.54 1970.81 1602.9 724.0 -144.3 -34.6
Ar 16.330 1.20 652.35 339.2 — — —
NO 2.790 0.20 83.72 82.3 -5.7 31.6 -13.4
n2o 2.190 0.16 96.39 50.8 139.4 -92.7 22.8
h2o 173.431 — 3124.41 5647.3 13.8 2296.1 -790.4
Total 1531.428 100.00 41 647.41 45 453.8 -5683.8 18 900.2 -7150.3

Average molar mass of exit gas stream = 41647.41/1531.428 = 27.20

Reference temperature, T0 = 298.15 K
Heat input to absorber (of gas stream)

31315
09= j (47 968.2-4776.6 x 10-3 7+ 18 519.6 x I0-6 T2-7282.8 x 10_97"3)d7
298 15
= 720 459 kJ/h
= 200.13 kW
Heat in tail gas stream

32315
<pl0 = J (45 453.8 - 5683.8 x lO"3 7"+ 18 900.2 x lO-6 T2 - 7150.3 x K)-9 T3) dT
29815
= 1132 458 kJ/h
= 314.57 kW
Heat of reaction (Ref. 1):
AH0R = 2 (-174.10) - [2 (90.25) + 1.5(0) + (-285.83)]
= -348.2- 180.5 + 285.83
= -242.87 kJ/2 mol NO reacted
= -121.435 kJ/mol NO reacted (exothermic)
Total heat generated during reaction:
0,, = 121.435 x 1000 x 135.63
Process Engineering Channel

= 16 470 229 kJ/h

s 4575.06 kW
Water evaporated in absorber = 173.805 - 46.629
= 127.176 kmol/h
= 2291.1 kg/h
Assume average condensation temperature of 450C.
@ProcessEng

A at 450C = 2394.9 kJ/kg (Ref. 2)

Heat absorbed during evaporation,
</)|2 = 2291.1 x 2394.9
' = 5486 955 kJ/h = 1524.15 kW
Strength of aqueous acid at the bottom of the absorber = 58%
Total HNO3 produced = 135.65 kmol/h
= 8547.69 kg/h (100%)
 Stoichiometry

a
Aqueous ....
acid produced = 8547-69
0-58
= 14 737.39 kg/h
Water in the acid = 14 737.39 - 8547.69
= 6189.7 kg/h
Fresh demineralized water input
= 6189.7 + (135.63/2) 18.0153 - (3853.58 + 840.04 - 3124.41)
= 5842.2 kg/h
= 5.84 m3/h
Since demineralized water is added at 250C, its heat input is zero.
^13 = ^
When HNO3 dissolves in water, heat change takes place (Ref. 1).
AH°of 58% HNO3 solution = -197.0 kl/mol HNO3
AH] of 100% HNO3(0 = -174.2 kJ/mol HNO3
Heat change = -197.0 - (-174.2)
= -22.8 kJ/mol HNO3 (exothermic)
Heat evolved by dissolution of HNO, in water at 250C,
=22.8 x 1000 x 135.63
= 3092 364 kJ/h
= 858.99 kW
Heat capacity of 58% HNO3 = 2.64 kJ/(kg • K) (Ref. 1)
Enthalpy of liquid 58% HNO3 over 298.15 K
= 2.64(313.15-298.15)
= 39.6 kJ/kg at 313.15 K
Heat of 58% acid at 40oC over 250C
(t>i5 = 8547.69 x 39.6
" = 338 488 kJ/h
= 94.02 kW
Heat of secondary air at 40oC

31315
8145 2
016 = , f (37 832 - 1968.3 x lO"3 T+ 129 523 x lO"6 T
29 394
^298-15 - 5254.9 x lO"9 r3) dF

8145x574358
Process Engineering Channel

= 159 153 kJ/h

29 394
s 44.21 kW
Enthalpy of condensate, entering absorber:
</)|7 = 3853.58 (40 - 25) 4.1868
= 242 013 kJ/h
= 67.23 kW
@ProcessEng

Heat to be removed by cooling water

= 09 + 011 + 013 + 014+ 016 + 017 _ 010 _ 012 _ 015
= 200.13 + 4575.06 + 0 + 858.99 + 44.21 + 67.23 - 314.57 - 1524.15 - 94.02
= 3812.88 kW
Cooling water is supplied to internal coils at 320C and leaves it at 370C.
 Introduction to Process Engineering and Design

Required cooling water flow rate, mcw

3812-88x3600
5x4-1868
= 655 697 kg/h
= 655.7 m3/h

An example relating to absorption of formaldehyde in water to produce 37%

aqueous solution is solved as Example 9.5 in Chapter 9. Both these examples
refer to absorption with heat of absorption.

Exercises

2.1 A cylinder is filled with 6 Nm3 hydrogen. Its pressure and temperature are 150 bar
g and 350C. If the actual specific volume of hydrogen at these conditions is 0.1847
nrVkmol, what is the geometric capacity of the cylinder? Instead of using actual
specific volume data, if ideal gas law is used for calculations, what will be the %
error?
2.2 The chloride of some element contains 90.8% chlorine (by mass). What is the for-
mula of the chloride compound ?
2.3 A mixture, amounting to 18.3 kg of a trivalent metal and its oxide, is dissolved in
32.0 kg sulphuric acid having 98% strength. The mixture reacts with stoichiometric
amount of sulphuric acid and forms metal sulphate. There is no excess sulphuric
acid leftover. Calculate the composition of the mixture.
2.4 Complete combustion of an alkane produces water vapour, equivalent to the oxy-
gen consumed (on mole basis). Find the alkane.
2.5 Nitration product of a hydroxybenzene [C6H(6_a)(OH)a] contains 49% oxygen by
mass. Determine the structure of the compound.
2.6 Reduction of nitrobenzene is to be carried out in a batch reactor. At the end of the
reaction, aniline is steam distilled and collected in a receiver at 40oC. Distilled
mass is separated in two layers. Top layer is decanted in another vessel and meas-
ured to be 910.2 kg. Bottom layer is measured to be 1089.8 kg. It is known from the
literature5 that top aniline rich layer contains 94.3% aniline while the bottom aque-
ous layer contains 3.83% aniline by mass at 40oC.
(a) Calculate total aniline distilled.
Process Engineering Channel

(b) Assume that all aniline, produced during reaction, is distilled out. If 1200 kg
nitrobenzene was charged to the reactor and conversion is 100%, what is the
yield of aniline?
2.7 Ethylene chlorohydrin and sodium bicarbonate are reacted in a continuous stirred
tank reactor. Reaction takes place as given in the following equation at 110 kPa a
and 820C.
ch2oh ch2oh
@ProcessEng

+ NaHCOj = | ' + NaCl + CCb

CH2C1 ch2oh
Aqueous solution of 30% of ethylene chlorohydrin and aqueous solution of 15%
NaHCOj (both by mass) are fed to the reactor in equimolar proportion. Conversion
of the reactants is 95% while the yield of ethylene glycol is 100%. Calculate the
mass % and mole % compositions of the product stream.
 Stoichiometry

Carbon dioxide, produced during the reaction, is vented out at 110 kPa a and 820C.
Calculate the concentrations of carbon dioxide, water vapour, ethylene chlorohydrine
and ethylene glycol in the vent gas stream. Assume ideal behaviour of the liquid
mixture.
Data:
(a) Vapour pressures of water, ethylene chlorohydrine and ethylene glycol at 820C
are 51.329 kPa, 17.065 kPa and 0.79 kPa, respectively.
(b) Lowering of vapour pressure of water due to the pressence of inorganic salts
(NaCl + NaHCC^) having less than 10% concentration (by mass) in water at
820C is 2.62 kPa.
2.8 Effluents generate at various locations in a composite textile unit. Reject water
from reverse osmosis plant for production of water for boiler feed (BE) make-up
purpose, boiler and cooling tower blowdowns, dye-house effluents, fabric washing
liquor, etc. collect in a pit. Raw water from an underground source and combined
effluent analyses are given in Table 2.9.

Table 2.9 Analysis of Raw Water and Combined Effluent

Parameter Raw water Combined

Effluent

pH 7.8-7.9 7.5 - 7.9

Dissolved solids (DS), mg/L 1250 12 600
Total hardness as CaCCT,, mg/L 230 500
Permanent hardness as CaCOj, mg/L Nil Nil
Calcium hardness as CaCO,, mg/L 170 375
Total alkalinity as CaCO^, mg/L 310 1190
Chlorides as Cl. mg/L 320 6260
Sulphates as SO4, mg/L 156 210
Silica as SiCL. mg/L (max.) 3 30
Suspended solids, mg/L (max.) Nil 100
Chemical oxygen demand (COD), mg/L (max.)-
dichromate value Nil 800
Biological oxygen demand (BOD), mg/L (max.) Nil 75
Oil and grease, mg/ L (max.) Nil 3
Colour None Dark
Process Engineering Channel

At first, the textile unit adopted primary and secondary treatments for removal of
oil, grease, suspended matter (< 30 mg/L), COD (< 250 mg/L), BOD (< 30 mg/L)
and colour. Effluents with nearly 13 000 mg/L DS after these treatments used to go
to solar evaporation lagoons. Capacity of the plant was 100 nrVd.
Shortage of water of underground source over a period forced the textile unit to
consider integrated additional treatments for recovery of water for reuse. The unit
requires about 75 nrVd of raw water for BE Make-up purpose for passing through
@ProcessEng

the reverse osmosis (RO) plant.

In the newly designed treatment facility (see Fig. 2.1) effluent from the existing
treatment plant is first passed through an ultrafilter in which multicapillary hollow
fibre membrane is used. This filter acts as a polishing filter in which suspended
solids, organic impurities, colloidal silica, etc. are removed. Clear effluents with
nearly same composition (in terms of inorganic compounds) and 12 250 mg/L DS
 Introduction to Process Engineering and Design

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Process Engineering Channel

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@ProcessEng

oo

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 Stoichiometry

is passed through two stage RO units. In the first stage, spirally wound membranes
for brackish water are housed. Effluents enter at 25 bar g to this unit. Recovery of
62% is achieved as permeate which contains 520 mg/L DS and 275 mg/L chlorides
(as Cl). Reject from the first unit is pumped to 50 bar g and passed through the
second stage of the RO unit. This unit houses spirally wound membranes, designed
for high solids brackish water desalination. Recovery of 28% is achieved from the
second stage as permeate which contains 960 mg/L DS and 486 mg/L Cl. Perme-
ates from both the stages are collected, mixed and passed through the existing re-
verse osmosis plant at 10 bar g to produce BF make-up water.
Reject from the second stage RO plant is pumped again to 7.5 bar g and passed
through a nanofilter. In this unit, special spiral wound membranes are housed which
selectively removes chlorides in the permeate. Recovery from the nanofilter is 90%
in which 95% of the chlorides, present in the feed, are dissolved. Reject from the
nanofilter is sent to solar evaporation lagoons.
(a) Calculate the total permeates, available from two stages of RO system. Check
whether this quantity is adequate for production of BF make-up water.
(b) Brine (i.e. permeate with high chlorides from the nanofilter) is reused for
production of 12% NaCl solution for dyehouse. Calculate the flow rate and
concentration of brine.
(c) Calculate the reduction in final effluent, discharged to solar evaporation
lagoons.
Hint: Assume chlorides as NaCl at all points in the treatment plant.
2.9 Ethyl benzene is an important intermediate for the manufacture of styrene. This
intermediate can be manufactured by reacting benzene with ethylene over a catalyst
in vapour phase. Patented Mobil-Badger process uses Zeolite as catalyst. Chief
reaction can be written as under.
C6H6 + CH2 = CH2 = C6H5CH2CH3
Benzene Ethylene Ethyl benzene
Alkylation reaction does not stop at monoethyl benzene but a part of ethylbenzene
is further alkylated to diethyl benzene, triethyl benzene, etc., collectively referred to
as polyethyl benzenes.
C6H5CH2CH3 + CH2 = CH2 = CH3CH2C6H4CH2CH3
Ethyl benzene Ethylene Diethyl benzene
A high benzene to ethylene ratio in the feed gives a low polyethyl benzenes to
ethyl benzene ratio in the product stream. Excess benzene is recovered from the
product gas stream and recycled to the feed.
Process Engineering Channel

While pure ethylene stream can be used as a feed, dilute gas stream, such as
treated off gas mixture from Fluid Catalytic Cracking (FCC) unit of a petroleum
refinery with low ethylene concentration, can also be used as the feed.
Figure 2.2 is a simplified flow diagram of the process. Fresh benzene is vaporized
and mixed with recycled benzene vapours. Ethylene in the form of offgas mixture
from a FCC unit of refinery, having molar composition of CH4: 37%, C2H6: 19%,
C2H4: 19%, H2: 9%, N2: 13% and CO; 3%, is compressed to 12 bar g and fed to the
@ProcessEng

reactor after heating in a heater, using molten salt.

Reactor has three 3 catalyst beds and operates at 12 bar a. Offgases are heated
and sent to first bed. An overall molar ratio of 10 : 1 of benzene to ethylene is used
for the reaction. Of the total benzene, 40% quantity is fed to the first bed at 350oC.
Assume 50% conversion of ethylene in the first bed with 90% yield to ethyl ben-
zene. Offgas temperature is so controlled that the product gas mixture from the first
bed is maintained at 420oC. A definite quantity of benzene at 300oC is mixed into
 Introduction to Process Engineering and Design

Recycle Benzene

Fresh Benzene 350 C

Molten Salt
Molten Salt

Reactor

Molten Salt Bed 1

Offgases
from FCC Unit*" | 300 C 420 C
Quench I

Compressor Bed II

300 C 400 C
Quench II

Bed III

> ■ Product Gas

Process Engineering Channel

Mixture
Fig. 2.2 Manufacture of Ethyl benzene

the production gas mixture from the first bed. In the second bed additional 25%
conversion of ethylene (on total feed basis) is achieved with 90% yield to ethyl
benzene. Temperature of product gas from the second bed is maintained at 400oC.
The product gas mixture from the second bed is quenced with balance quantity of
@ProcessEng

benzene at 300oC. In the third bed, rest 25% conversion takes place with 90% yield
to ethyl benzene. All polybenzenes may be assumed as diethyl benzene for calcula-
tion purpose.
 Stoichiometry 37

Table 2.10 Data on Gaseous Components

Component Formula AHf, Gaseous Heat Capacity

(gas) Equation Constants at 1 bar
kJ/mol at
1 bar & 25"C a b x 103 cx 106 dx 109
Benzene c6h6 82.93 -37.99 490.42 -321.39 79.36
Methane ch4 -74.52 19.25 52.11 11.97 -11.32
Ethane c2h6 -83.82 5.41 178.09 -67.37 8.71
Ethylene C2H4 52.50 4.13 155.02 -81.55 16.98
Hydrogen H2 0 28.61 1.02 -0.15 0.77
Nitrogen N2 0 29.59 -5.14 13.18 -4.97
Carbon monoxide CO -110.53 29.12 0.25 -2.07 5.90
Ethyl benzene CsHio 29.92 -36.72 671.12 -422.02 101.15
Diethyl benzene CioHH 22.27 -37.41 867.09 -556.0 141.10
Source of data: Ref. I

Calculate: (a) Required temperature of the offgas mixture, entering the first bed. (b)
Benzene fed (in % of total) to the second bed as quench and (c) Temperature of
product gas stream, leaving 3rd bed.
Note: Assume that enthalpy of formation and heat capacity data of 1 bar are valid
at 12 bar a.

References

1. Bhatt, B. 1. and S. M. Vora, Stoichiometry, 4th Ed., Tata McGraw-Hill Publishing

Co. Ltd., New Delhi, 2004.
2. Bhatt, B. I., Design Databook, Properties of Steam, Selected Refrigrants, n-Hexane
and Brines, CBS Publishers & Distributors, New Delhi, 2006.
3. Himmelbalue, D. M., Basic Principles and Calculations in Chemical Engineering,
5th Ed., Prentice-Hall of India Pvt. Ltd., New Delhi, 1994.
4. Smith, J. M., H. C. Van Ness, M. M. Abbott and B.l. Bhatt, Introduction to Chemi-
cal Engineering Thermodynamics, 6th Ed., Tata McGraw-Hill Publishing Co. Ltd.,
New Delhi, 2003.
Process Engineering Channel

5. International Critical Tables, Vol. 3, McGraw-Hill, USA, 1928, p. 389.

6. Chopey, N. P., Handbook of Chemical Engineering Calculations, 2nd Ed., McGraw-
Hill, Inc., USA, 1994.
7. Kapoor, K. L., Numerical Problems in Chemistry, Tata McGraw-Hill Publishing
Co. Ltd., New Delhi, 1991.
8. Reklaitis, G. V. and D. R. Schneider, Introduction to Material and Energy Bal-
ances, John Wiley & Sons, USA, 1983.
@ProcessEng

9. Hougen, R. A., K. M. Waston and R. A. Ragatz, Chemical Process Principles,

Part-I, CBS Publishers & Distributors, New Delhi, 1995.
10. Fedler, R. M. and R. W. Rousseau, Elementary Principles of Chemical Processes,
2nd Ed., John Wiley & Sons, USA, 1986.
 Chapter
-j

Process Engineering

3.1 INTRODUCTION

A process is simply a method by which products can be manufactured from the

raw materials. Selection of process steps for the manufacture of the product to
the required specifications is the job of a process engineer. There could be number
of methods to manufacture the same product. The best method for manufacturing
a product has not yet been discovered nor can it be said that a job can be per-
formed in only one way. The process engineer faces alternative solutions to manu-
facturing problems. This possibility comes out of a combination of factors such
as information gained by him from the past processes, imagination, his own knowl-
edge of known processes, etc. However, economy of manufacture is a factor that
frequently decides the best route to be followed. Thus, it is safe to say that inno-
vation, imagination and economy are the key factors in process engineering.

3.2 EXAMPLES OF ALTERNATIVE ROUTES IN

PROCESS ENGINEERING

Process engineering and design can be explained best with the following illustra-
tions.
1. Consider treatment of water for various end uses. End use of treated water
is a chief governing factor in deciding the process steps to be selected.
Process Engineering Channel

Production of drinking water demands different steps as compared to pro-

duction of high quality water for boiler feed (BF) make-up purpose.
Drinking water requirements can be met by different water treatment
steps. If water contains less dissolved solids, say less than 500 mg/L, clari-
fication and disinfection by chlorination could be satisfactory. However, if
raw water has high dissolved solids, dual filtration followed by desalination
@ProcessEng

by reverse osmosis and pW adjustment would be necessary. These are rela-

tively simple process steps.
In case of BF make-up water requirements for high pressure boilers,
number of routes of the process are possible. Clarification, activated car-
bon treatment and demineralization by ion exchange is one route. How-
ever, this route may not be economical if raw water has high dissolved
 Process Engineering

solids (say more than 1500 mg/L). In the latter case pre-treatmenl, reverse
osmosis treatment, followed by ion exchange treatment would become nec-
essary. The final process route to be followed will depend on raw water
quality, operating pressure of the boiler, effluent disposal problem, etc.
2. In another case, consider the classic example of production of anhydrous
(100%) ethanol. Ethanol produced by fermentation of molasses can be first
distilled to produce azeolropic mixture (containing 95.6% alcohol by mass)
which can be further dehydrated to 100% by use of an entrainer such as
benzene in azeotropic distillation. New development of pervaporation
process can be used in place of azeotropic distillation. Similarly, drying of
azeotropic mixture by using molecular sieve beds can be also employed.
Innovations thus have a strong impact on process design alternatives.
3. Partially hydrogenated edible oils are extensively used for variety of appli-
cations. It is normally manufactured by hydrogenation of an edible oil in
presence of a nickel catalyst under pressure (say at 2 bar g) and at 140 to
160oC in an autoclave. In a batch process, the reactor can have an anchor
agitator with convolute at the top of the liquid level for proper mixing of
hydrogen with the oil. This age old technology is replaced by installing a
gas induced agitator (may be a lube type) which can result in a better product
in a shorter period. This innovation has several advantages over the
conventional design. Further research has demonstrated that use of carbon
dioxide along with hydrogen at high pressure results in a product with
stringent specifications (e.g. with less trans fatty acids).
4. Modern ammonia plants are large size plants (1800 t/d or more) which are
continuous and reliable. These are quite compact than those originally de-
veloped to operate at very high pressures. Also, newer plants are safe and
highly energy efficient proving the economy of the scale.
Several examples can be cited where technological developments have totally
changed the manufacturing methods. This can be attributed to newer technolo-
gies, efficient equipment designs, use of alternate raw materials, etc. Process
engineer's job is, therefore, to evaluate various alternatives available to him and
decide over the best method to be adopted. Batch type hydrogenation plants are
still preferred over continuous one due to many reasons such as relatively small
Process Engineering Channel

capacities, different feedstocks for different batches, safety in handling, etc. De-
sign of ammonia plants are currently more guided by available raw material and
specific energy consumption. Thus it cannot be said that the best method for
manufacturing a product can be performed in only one way. The possibility
of alternate process operations comes as combination of information gained
from the past, imagination and the process engineer's knowledge of the known
processes.
@ProcessEng

3.3 GENERALIZED APPROACH TO THE CHEMICAL

PLANT DESIGN

Design of chemical plant involves chemical technology, unit operations, instru-

mentation/controls, use of specialized equipments, safety considerations, materi-
als of construction, etc. Chemical technology is the branch of chemical engineer-
 Introduction to Process Engineering and Design

ing dealing with chemical changes and physical methods involved in industrial
process. It is necessary to supplement the knowledge of unit operations with
considerations of chemical technology in order to obtain a concept of the com-
plete plant.
From the above discussions, it is clear that before attempting process engi-
neering design it is necessary to fix the product specifications. Capacity of the
plant can then be decided based on demand and/or investment. Evaluation of
available technologies will have a say on investment. In order to arrive at con-
sumption figures of raw materials and energy, preliminary stoichiometric calcu-
lations would be necessary. This would give some rough idea of cost of produc-
tion due to inputs which normally accounts for higher proportion in the cost.
Following sequence might be followed in implementation of the project right
from conception of the idea to construction and operation of the plant.
(i) Process Research (iv) Process Development
(ii) Preliminary Process Design (v) Final Process Design
(iii) Preliminary Process Evaluation (vi) Final Process Evaluation

3.3.1 Process Research and Pilot Studies

Chemically feasible process is fundamentally characterized by process research.

It is an accepted fact that process research is a basic necessity of the process
industry. Orderly research and development has become an integral part of all
leading industrial organizations and is synonymous with the progress. Basic op-
erating conditions are explored and sufficient information is obtained from proc-
ess research for preparing a preliminary material and energy balance flow sheet.
In many instances, development of a pilot plant is a necessity, particularly
where laboratory scale data are not sufficient to scale-up or safety aspects are not
well known. It is better to commit blunders on a small scale and make profits on
a large scale. Such pilot plants can result in eliminating production of the off-
spec product, good yields, reduced cost of manufacturing, etc. by fixing best
operating conditions, installation of corrosion resistant plants, deployment of best
equipment, reduced recycles due to better yields and so on.
Need for a pilot plant is justified in any manufacturing (Refs 1, 2 and 3). Take
for example, manufacture of bulk drugs. Manufacture of antibiotics involve reac-
Process Engineering Channel

tions (of exothermic nature) at very low temperatures; at times at cryogenic tem-
peratures. Use of ice or dry ice suffice at laboratory scale but at production level
it is necessary to deploy industrial refrigeration which can be simulated in a pilot
reactor. Design of a reactor changes significantly with industrial refrigeration in
which possibly use of liquid nitrogen may be necessary. Similarly, solvent to
reactant ratio used at laboratory scale may not be economically viable at the plant
scale and it may be necessary to reduce the ratio to an optimum by experiments
@ProcessEng

on a pilot scale.
As seen in the earlier section, hydrogenation of edible oil is carried out in a
slurry comprising of a catalyst. Selection of agitator is crucial. Pilot studies are
valuable in the development of an agitator ideally suited for the reaction. Simi-
larly, ozonation is a dangerous reaction and is very much dependent on intensive
 Process Engineering

diffusion of gas in the liquid. Use of a static mixer with liquid circulation and
simultaneous injection of ozone in it could prove to be advantageous. However,
such designs should be supported by pilot studies for its efficacy and control of
reaction. Design of a seal for agitator can become an important design factor
when dealing with high pressure gas reactions or with dangerous gases such as
chlorine, ozone, etc. Viscosity of reactant mass, operating pressure and tempera-
ture, suspended solids concentration, heterogeneous reaction mixture, etc. can
have a strong bearing on reactor design and process research with a pilot plant
could therefore be fully justified.
Pilot scale studies may be warranted for other unit operations. Its requirement
can be decided based on the data available in literature or from the lab scale
experiments. For example, if sufficient vapour-liquid equilibrium data are avail-
able for separation of a liquid mixture, a distillation equipment can be designed
with certainty and pilot study may not be required. Similarly, mutual solubility
data, if available, extraction equipment design can be carried out with known
principles of unit operations. In the event of a specific design of the equipment,
pilot studies are recommended. For example, for carrying out high vacuum distil-
lation of a heat sensitive product, specialized equipment such as short path distil-
lation or a wiped film evaporator is recommended. Manufactures of such
equipments provide pilot study on a small scale equipment with reasonable scale
up confidence.
Pilot scale study can provide more reliable flow sheet than the one obtained
from lab scale study. Versatile equipments which can be procured off the shelf
are available for pilot studies. Alternately process engineers can design a tailor
made pilot scale equipment for the study.
Pilot plant can be used for ongoing improvements of the existing process or
development of a next generation process. One of the objectives of such a study
is substitution of a raw material. Improvement in product quality, reduction in
process costs, safety and minimizing the pollution effects are other objectives of
the pilot study.
Introduction of a new product adds a dimension of risk relative to the existing
product. Manufacturing a small volume of the new product in a pilot plant can be
valuable in supplying it for commercial testing to a customer whose evaluation is
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crucial before introducing the product on a commercial scale. In many instances,

when the customer demands some product specifications change, it could be
achieved by process research on a pilot plant.
It can, therefore, be said that a pilot plant is an intermediate sized plant, modeling
the process of interest, constructed and operated so as to test the model in a
convenient, less expensive and safe manner.
Results obtained in the pilot plant builds confidence in management and help
@ProcessEng

them in taking commercial, technical and financial decisions, there by focusing

their attention and allocating the resources accordingly.
Cost of a pilot plant could be significant but risks are relatively low and payoffs
could be substantial.
Another important consideration in pilot plant operation is the selection of
manpower. A project leader (a chemical engineer), familiar with the chemical
 Introduction to Process Engineering and Design

process and the equipments, is chosen for the job. He should be assisted by one
or more chemists, depending on the size and complexicity of the pilot plant.
Careful observations during the operation and interpretation of data are the skills
desired from the personnel. Effective communication among the staff is crucial.
Cost of such talented staff would be high but is rewarding. Motivation to the staff
enhances self satisfaction and increases dedication towards the work.
Logging of data can range from visual examinations to instrument readings.
Relatively inexpensive data aquisition system based on electronic instruments is
available which can be installed and connected to a computer to record the data,
generate trend analysis, know critical events, find temperature or pressure spikes,
etc.
Instrumentation needs for the pilot plant depends on its complexicity. A rea-
sonably straight forward process may not justify complex instrumentation/control
system but a high pressure and hazardous pilot plant will call for an expensive
instrumentation package. Take for example, a pilot plant for the manufacture of
alkyd resins or antibiotics require normal instrumentation. However pilot plants
for hydrogenation, ozonalion, supercritical extraction with carbon dioxide,
carbonylation with carbon monoxide, etc. may call for full automatic operation
with data logging systems.
Pilot plant can be used as a training tool to plant operating personnel. It is well
known that aeroplane pilots are trained on a simulator. Pilot plant can be consid-
ered as a simple version of 'simulator' of the main plant.
Project leader will be able to prepare a preliminary operating manual of the
main plant based on his study of the pilot plant. Pre-startup testing, startup, nor-
mal operation and shutdown, emergency shutdowns, etc. can be well visualized
by the project leader. The manual can be subsequently updated by the plant per-
sonnel based on their operating experience.
A process flow diagram can be offered by a team leader for further process
design based on pilot plant studies.

3.3.2 Process Design and Development

After carrying out process research and pilot plant study, the process details are
now available to the process engineer which can be scaled up with sufficient
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confidence level to a commercial plant. Immediately the process engineer is not

concerned with detailed design of pieces of equipment but is concerned with the
overall process covering following major items.
(a) Preparation of a block diagram for presentation to the management for pre-
liminary feasibility of the project.
(b) Carryout overall and individual material balances showing the yield and
quality of all materials to and from all pieces of equipment.
@ProcessEng

(c) Heat balances over each piece of equipment.

(d) Prepare a Process Flow Diagram based on data to steps (b) and (c).
(e) Establish flow quantities and suction and discharge conditions of all rotat-
ing equipments.
(f) Size reactors and storage tanks.
 Process Engineering

(g) Separation process calculations with optimum operating conditions to

effect the desired separation.
(h) Estimate utility requirements such as steam, cooling water, refrigeration,
electricity, thermic fluid, fuel, etc.
(i) Prepare a Piping and Instrumentation Diagram so that requirement of
instrumentation/control system is assessed.
(j) Develop a tentative layout of the plant that should take into considerations
of safety requirements.
(k) Estimate preliminary capital investment and production cost.
Preliminary process design is necessary to find economic viability of the project
and focus on important practical aspects. Take for example carbonylation of ethanol
to propionic acid. This is high pressure and high temperature catalytic reaction of
ethanol and carbon monoxide. Toxic nature of carbon monoxide dictates promi-
nently in deciding over the safety requirements and practical operational aspects
over the economic viability of the project.
Preliminary design will show the preferred process and whether further re-
search and development (R & D) work is necessary. This additional R & D ef-
forts will be specifically targetted to obtain missing information. Many a times
physical properties of intermediates, corrosion data, heal of reaction, etc. are not
available in literature and may have to be obtained by R & D efforts.
Duration of completion of project can be predicted based on the preliminary
design. Based on this information, marketing strategy of the product can be de-
veloped.
Development of PFD and P & ID are dealt in detail in Chapter 4 with specific
examples.
After completion of the preliminary process design and its evaluation,
detailed process design work is taken up. For the detailed design, variety of 'tools'
are used in calculations. Estimation of properties by group contribution methods,
literature search for correlations for heat transfer, pressure drop and mass trans-
fer calculations, mixing, etc. are the tools available to a process engineer. Many a
times empirical sizing of equipment is carried out based on experience or litera-
ture survey. Numerous process design examples are worked out in Chapters 5 to
10 relating to fluid flow, heat transfer and separation processes.
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Instrument engineer is simultaneously consulted in selecting the final control

strategy. Suggestions/comments of the project leader of the pilot plant are quite
valuable on the preliminary PFD and are incorporated as far as possible.
On completion of all the above steps, final PFD and P & ID are prepared by
the process engineer and handed over to the project manager with equipment
datasheets (containing process specifications) for further execution of the project.
During project execution stage also, role of the process engineer cannot be
@ProcessEng

undermined. Fie will have an advisory role to ensure that process will function
smoothly as anticipated during design stage.

3.3.3 Batch vs Continuous Operations

When designing processes or facilities for some applications, process engineer

 Introduction to Process Engineering and Design

must approach the task differently than he would for a project in other chemical
process industries. Bulk drugs, pharmaceutical intermediates, dyes intermedi-
ates, fine chemicals, etc. are the products in which batch operations dominate.
Take the pharmaceutical industry sector. In this sector, lots of manufactured product
are required to be segregated. In this way waste is minimized and regulations
could be easily conformed to. Secondly, most pharmaceutical processes deal with
relatively smaller amounts of material than with typical chemical processing
operations. For this reason, batch processing equipment is often the preferred
choice. Many a times, an equivalent continuous based unit operation that is small
enough to accommodate the volume of material to be processed is not available.
Further, most pharmaceutical processes come out of the lab where operations are
predominately in batches. These batch type processing techniques migrate to the
larger production scale.
Although one would not propose changing batch processes to continuous proc-
ess for small volumes, many operations could be made continuous. A continuous
unit operation can be used to process a tank, full of material. For example, a
continuous filtration method, such as a rotary drum filter can be used instead of
batch method such as a plate and frame filter.
Another example of making continuous unit operations work involves two
phase extraction process. The traditional batch approach is to use a simple mixer-
settler that mixes two phases together in a tank before they are allowed to sepa-
rate. In a continuous analog, a small extraction column could be used in which
two phases flow past one another continuously to facilitate phase contact. This
continuous operation can be performed in a much smaller equipment. It also
provides numerous 'stages' of phase contact resulting in more efficient mass
transfer operation. Similar examples can be cited for fermentation, precipitation,
crystallization, drying, etc.
Conversion from batch processing to continuous processes would thus allow
smaller equipment with lower capital cost. Continuous equipment could be de-
signed to be enclosed and cleaned easily, allowing the use of less costly produc-
tion space. Many of these continuous equipment would operate at 'steady state'
and it would be easy to automate them, reducing labour cost.
Batch operations and the equipment that facilitate them are by no means obso-
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lete. Continuous equipment by its nature must be designed around a standard

process that will be repeated for a significant period. For products that are made
infrequently it is impractical to design continuous operations to support them.
Processes where the input material varies over time also exist. These applications
require an adjustment to the processing techniques to accommodate new vari-
ables. In many such cases only batch operations are flexible enough to handle
these situations. Further some processes handle materials that are so valuable or
@ProcessEng

hazardous that the transients that might occur in a continuous process are unac-
ceptable. In these cases, only batch processes offer the control and containment,
required to make them successful.
Continuous extraction of oil from oil-rich cake with n-hexane is practiced in
industries on large scale. However, when residual oil is to be extracted from
 Process Engineering

bleaching earth before its disposal, a batch operation is normally performed as its
quantity is quite small.
Bleaching of edible and non-edible oils was performed traditionally in batch
equipment. Recent development of continuous bleachers give better quality of
bleached oil with less bleaching earth/activated carbon and eliminate need for
intermediate storage of bleached oil before its passage to continuous deodorizer.
Also, the size of a continuous bleacher is much smaller than a batch bleacher.
Many a times, solvent to reactants ratio is kept high (may be in excess of 15) in
a batch reactor based on lab studies. Many of such reactions could be relatively
fast and endothermic. At the end of the reaction, solvent is required to be distilled
out. Such a process lends itself for conversion to continuous operation. A mixed
stream of solvent and reactants (possibly with much lower ratio) can be heated in
a standard shell and tube heat exchanger, passed through a mixing equipment
(such as a static mixer) and sent to a reactive distillation column where sufficient
reaction time can be provided and simultaneously solvent is distilled out. Such a
conversion can result in substantial energy savings apart from reduced time cycle
of production.
Large capacity chemical plants are continuous in nature. Manufacture of am-
monia, methanol, acetic acid, carbon black, formaldehyde and many others are
the examples where continuous plants are designed and operated. Consistent
quality, optimum energy input, lower cost of installation of plant per unit (say kg)
of product, etc. are inherent benefits of continuous plants.
The process engineer must evaluate both the operations before deciding the
best operation, suited for the product. As explained in previous paragraphs, batch
operations should be restricted to a minimum so that economy of scale, a feature
of continuous operations, can be availed at a large.
Reference 4 deals exclusively on batch process design.

3.4 PREPARATION OF OPERATING INSTRUCTIONS

MANUAL

One of the less appreciated tasks of a process engineer is preparation of an Op-

erating Instructions Manual (also known as Operation Manual) — OIM of the
plant. When a calculator is purchased, a leaflet is provided alongwith the calcula-
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tor which describes its functioning. In a similar fashion, OIM is prepared for
safe, smooth and efficient operation of the plant. Well prepared OIM serves as a
tutor to the operating personnel. It is also a valuable reference tool in day to day
operation.
Safe operation of the plant is the prime objective of preparation of the manual.
Therefore, safe operating limits are prescribed clearly for each equipment and
@ProcessEng

process. Dangers, if any, of crossing the critical parameters must be underlined.

Start-up and shut-down procedures are outlined in the manual. These include
purging, slow pressure build-up, well defined heating procedure, etc.
Normal operating procedures are covered for achieving optimum perform-
ance of the plant. These procedures cover desired operating parameters' range,
generation of minimum effluent quantity, optimum utility consumptions, etc.
 Introduction to Process Engineering and Design

Emergency handling procedures are well covered in the manual. Power failure,
leakages, utility failure, fire, etc. are the emergencies which must be well thought
of and a plan of each emergency must be described.
PFDs and P&IDs are included in OIM. Wherever required, additional sketches
are included to clear the operational aspects. Calibration charts of tanks, reac-
tors, dosing systems, etc. are included in OIM. For example, capacity of a screw
feeder with its speed is an essential requirement of an operator.
Process datasheets and manufacturers' datasheets are normally compiled as
Equipment Datasheets and it is a separate manual by itself. Instrument specifica-
tions are also included in this manual.
Useful guidelines are drawn from the pilot plant operation for the preparation
of OIM. Equipment and instrument supplier catalogues provide their own oper-
ating instructions. OIM should cover comprehensively operating instruction of
the manufacturers.
In many instances, standby pumps, filters, etc. are provided. Periodic opera-
tion of standby equipments is to be included in OIM. Similarly, periodic calibra-
tion of instruments is needed to ensure that they are functioning in order. For
example, in case of pressure gauges, zero error is checked periodically. In case of
temperature measuring instruments, calibration with a standard instrument is rec-
ommended periodically.
Preparation of OIM is normally undertaken by the process engineer during
project execution. Draft copy of OIM is circulated to operating personnel and
project leader of pilot plant. Suggestions received from them should be critically
reviewed and if found useful should be included in the final OIM.
Over a period of time, OIM needs upgradation as more experience is gained in
actual operation. Also the changes in OIM should cover the modifications that
are carried out over the years. Thus upgradation is a never ending process.
Preparation of log-sheets for manual logging of data is normally the job of
operating personnel. Neverthless, the process engineer can review the draft of
the log-sheets and may offer suggestions. For medium scale and small scale plants,
these are also known as batch sheets.
The process engineer should study the log-sheets periodically and offer sug-
gestions to the operating personnel. If necessary, OIM may require upgradation
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on account of review of the log-sheets.

3.5 CONDUCTANCE OF PERFORMANCE TEST RUNS

On installation of the plant, process engineer is required to conduct a perform-

ance lest of an equipment or entire plant. When a centrifugal pump is commis-
sioned, its capacity, head and power consumption are checked with the datasheet.
@ProcessEng

When a water treatment plant; say a reverse osmosis plant, is commissioned, its
performance is checked for permeate quality (vis-a-vis feed water quality), per-
meate/feed ratio and power consumption. In the same manner, performance of
cooling tower is checked for achieving anticipated cooling water temperature for
the prevalent wet bulb temperature of ambient air and for its power consumption.
In large chemical plants, performance guarantees are well specified in the con-
tract. These include product quality specification, raw materials consumptions
 Process Engineering

and utility consumptions. All these parameters are averaged over a specified con-
tinuous run of the plant, say for 120 hours or so. Average values are compared
with those guaranteed.
Conductance of performance test run requires specialized skills. It is carried
out by the process engineer in coordination with the plant personnel and contrac-
tor personnel. Before starting the test run, instruments are calibrated. Any spe-
cific deviation from normality is documented in the logsheet.
Test run report comprises logsheets, observation sheets, analytical reports and
summary of findings. It is used as Acceptance Report for the equipment or the
plant.

3.6 TROUBLESHOOTING

Troubleshooting is yet another task of the process engineer. During commission-

ing or normal operation, many operational problems are experienced. Some of
them are related to the process. Process engineer is required to study the prob-
lem, discuss with operating personnel and present a solution.
Take an example in which cooling water cools a fluid. If cooling is less effec-
tive than design, reasons for the same are to be determined. Less flow of cooling
water or high supply cooling water temperature or inadequate heat transfer sur-
face could be the problem for a new system. Material and energy balance across
the cooler will reveal the problem and corrective action can be taken. During the
course of operation, if the cooler performance deteriorates, fouling of cooling
surface could be anticipated.
Take another example of a separator in which organic liquid is separated from
water. While studying the performance of the separator, check moisture content
of the organic layer and chemical oxygen demand (COD) of the water layer. If
the results are not satisfactory in terms of separation, check operating tempera-
ture of the separator or its design.
In a distillation column, if the distillate quality is not maintained, one can
check the reflux ratio and other parameters.

3.7 COST CUTTING MEASURES

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In a normal running plant, process engineer has to consider cost cutting measures
in the plant. This is a never ending exercise as there exists an opportunity for
improvement in each plant. For finding the opportunity, indeplh study of the
plant is recommended.
Consider a chilling plant in which brine at -10oC is produced using refriger-
ant R-22. It is a known fact that in this temperature range Coefficient of Perform-
ance (COP) of ammonia refrigeration cycle is better than that of R-22 cycle.
@ProcessEng

Thus replacement of the refrigeration skid of R-22 system by ammonia system

will consume less power. However, fresh investment for the ammonia refrigera-
tion system will be needed. A cost benefit analysis will have to be carried out by
process engineer.
Take another case of a plant in which hot oil at 150-1750C is used to heat
reaction mass and carry out the reaction at around 105oC. Alternative system
 Introduction to Process Engineering and Design

with saturated steam at 3.5 bar g could be equally or more effective. Both eco-
nomical and practical aspects need be examined before any change in the plant is
considered.
In large chemical plants such as ammonia plants many oportunities exist for
cost reduction. With methane and ambient air as feedstocks at 250C, theoretical
energy consumption is 20.618 GJ/t ammonia. Actual ammonia plants consume
energy equivalent to 27 to 42 GJ/t ammonia, depending on the feedstock and
technology. This indicates a potential for reduction in energy consumption and
thereby in cost of production. Similar opportunities can be found in each plant.
Newer technologies and innovations can contribute significantly to cost re-
duction. Process engineering plays a vital role in their implementation.

3.8 GREEN ENGINEERING

A set of 12 guiding principles of 'green chemistry' were established by

Dr. P. Anastas and J. C. Warner in 1998 for creating safer chemicals and design-
ing for degradation to save the environment. Further to these guidelines, a
multidisciplinary group of engineering disciplines met in May 2003 in Florida,
USA to draft the principle of Green Engineering. The conference focused on the
definition of the scope and tone of green engineering relative to all engineering
disciplines; including chemical, mechanical, civil, electrical and environmental.
The objective of green engineering is to transform existing engineering disci-
plines and practices to those that promote sustainability. It incorporates the de-
velopment and implementation of technologically and economically viable prod-
ucts, processes and systems to promote human welfare while protecting human
health and elevating the protection of the biosphere as a criterion in engineering
solutions. To implement these solutions, engineers are advised to use the follow-
ing principles5.
(i) Engineer processes and products holistically, use systems analysis and in-
tegrate environmental impact assessment tools.
(ii) Conserve and improve natural ecosystems while protecting human health
and well-being.
(iii) Use life-cycle thinking in all engineering activities.
(iv) Ensure that all material and energy inputs and outputs are as inherently safe
Process Engineering Channel

and benign as possible.

(v) Minimize depletion of natural resources.
(vi) Strive to prevent waste.
(vii) Develop and apply engineering solutions while being cognizant of local
geography, aspirations and cultures.
(viii) Create engineering solutions beyond current or dominant technologies;
@ProcessEng

improve, innovate and invent (technologies) to achieve sustainability.

(ix) Actively engage communities and stakeholders in development of engi-
neering solutions.
Process engineer can play a vital role in achieving the objectives of green
engineering. At every stage of process engineering, the engineer must consider
and review whether the design adhers to the principles of green engineering. A
 Process Engineering

few examples will demonstrate implementation of principles of green engineer-

ing in practice.
(a) In solvent extraction plants, n-hexane is used to extract oil from oil-rich
cake. It is known that n-hexane is not totally safe for human beings. New
super critical extraction process based on carbon dioxide as an extracting
agent is found to be eco-friendly, safe for human beings and also gives
good quality oil.
Water can also be used as supercritical fluid to produce biocrude from or-
ganic waste. In this application, water is a safe extracting agent while it
helps in safe 'disposal' of organic (including hazardous) waste.
(b) Hydrogenated edible oils are used extensively in bakery and other food
products. Presence of trans-fatty acids in the hydrogenated fat is known to
be unfit for human consumption. Technological developments should be
targetted to produce the fat with low trans-fatty acids. One such develop-
ment is hydrogenation in presence of carbon dioxide at low temperature.
Another development relates to the use of noble metal catalyst (instead of
nickel) for hydrogenation.
(c) Methyl tertiary butyl ether (MTBE) is known an oxygenating product for
improvement of octane number of the gasoline. Research has revealed the
health hazards of MTBE when autovehicles emit gases to atmosphere.
Addition of anhydrous ethanol (a renewable product) is said to improve
octane number without creating health hazards.
(d) Trans esterification of fatty acids with methanol can produce biodiesel which
is considered an eco-friendly fuel for DG sets or for autovehicles. Fatty
acids can be obtained from edible and non-edible oils which are renewable
resources.
(e) Ozone depleting substances are threats to human beings. Montreal proto-
col, 1987 bans the use of certain chlorofluoro hydrocarbons which are es-
tablished to have very high ozone depleting potential, apart from their low
degradability. Classical example is dichlorodifluoromethane (CFC-12) which
is banned for use as a refrigerant, aerosole agent, etc. Engineers are advised
to use ammonia (R-717) or chlorodifluoromethane (CFC-22) in place of
CFC-12. Eventually CFC-22 is also to be phased out.
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(f) In a classical Bechamp process, nitro-compound is converted to a corre-

sponding amine by using iron power and water mixture. Reaction takes
long time. At the end of the reaction, total mass is required to be filtered out
of the iron sludge (fine in nature). Later the mass is separated in two layers.
Water, so separated, has high chemical oxygen demand (COD) and pose an
effluent-problem.
In new developed processes, hydrogen is used in presence of a catalyst
@ProcessEng

under pressure. Use of gas-induced agitator, nickel or noble metal cata-

lysts, etc. are the developments which result in reduced time of reaction
and also do not generate effluents. Thus, it is an eco-friendly process.
(g) While methanol is used as a solvent in many chemical plants, it is toxic to
human beings. Its use is considered unsafe in pharmaceutical and food
 Introduction to Process Engineering and Design

processing. Its higher homolog ethyl alcohol is safe for use in the industry
as a solvent.

3.9 PROCESS INTENSIFICATION

Process intensification can be defined as improving productivity of a system by

changing operational parameters and/or by carrying out desirable modifications.
In a process plant, improvement in productivity means product quality improve-
ment, yield/production rate increase, reduction in energy consumption, reduction
in other inputs (such as raw materials), safer operation, or reduction in pollution
load of the plant. Process intensification differs from troubleshooting (Sec. 3.6)
as the latter mainly focuses on solving the problems, faced by operating personnel.
Cost cutting measures (Sec. 3.7) can be considered as one of the objectives of
process intensification.
Process engineer can contribute significantly in process intensification; either
at the process design stage or in the running plant. Scientific approach to the
design and critical analysis and review of the operating data are the keys to proc-
ess intensification.
At the process design stage, a number of options are available to the process
engineer. Consider design of a multiple-effect evaporator system. Apart from the
process parameters; such as concentration of ingoing/outcoming solution, heat-
ing medium and its conditions (e.g. pressure and temperature), etc., process engi-
neer can design the evaporators with equal or unequal heat transfer area (HTA)
in the stages. Optimization techniques such as Evolutionary Operation (EVOP)
or dynamic programming can be used to find HTA for the both the alternatives,
thereby cost of the installed systems for both the alternatives can be worked out.
Optimum design of the system can then be selected.
A cascading type steam balance offers an interesting example of utility system
optimization as a part of process intensification. Modern heavy chemical plants
such as ammonia plant, methanol plant, ethylene manufacturing, petroleum re-
finery, etc. have cascading steam systems which can be optimized to consume
minimum fuel in the boiler and also reduce load on cooling tower. Reference 6
has given several steam balances for a given plant offering an opportunity to a
process engineer to select the best steam system.
Process Engineering Channel

In a simpler case, selection of an agitator in a reactor can result in substantial

energy saving-with improved agitation.
Linear programming is another tool which helps in optimizing the proportions
of components in a reaction mixture. Consider manufacture of alkyd resins by
reaction of polyols (such as glycerol) with fatty acids by azeolropic distillation
method. Fatty acids could be either distilled (pure) fatty acid or in the form of an
@ProcessEng

oil. Similarly, a variety of alcohols such as glycerol, sorbilol, etc. are used. Theo-
retical calculations can be made with the help of linear programming to achieve
desired properties of the product with best possible yield which can later be con-
firmed in laboratory trials.
Innovations and adoption of newer technologies are integral to process inten-
sification. Adoption of a standard operating practice in one industry into another
 Process Engineering

industry should be considered for a similar situation. A fluid bed cooler is used in
large urea plant to produce urea of uniform (narrow range particle size distribu-
tion) size prills at low temperature so that urea prills do not agglomerate to lumps
on storage in a silo which produce dust on breaking them. Similar problems are
also experienced in a carbon black plant. Adoption of the fluid bed cooler should
be considered in a carbon black plant.
Use of a static mixer in mixing an organic compound with a mixed acid (HNO3
+ H2SO4) to form nitro compound is found to be very effective in controlling side
reactions with efficient temperature control in a batch reactor.
Several examples can thus be cited to demonstrate that process intensification
at the design stage can result in a plant with lower operating cost, possibly lower
initial cost, ease of operation and safer operation.
In an operating plant, critical review of operational parameters can result in
substantial savings. Use of statistical methods are invaluable in this exercise. In
fact ISO 9001 gives stress on statistical methods for improvement in quality con-
trol which is advised as a continuous improvement process.
In a similar manner, it is advised that variation in process parameters and its
effect on plant performance be studied which can reflect the best and safer oper-
ating conditions.
Modifications in the plant can be aimed at reduction in energy consumption or
reduction in raw materials consumptions. In ammonia plants, purge gas from
synthesis loop was being vented or used a fuel in the furnace in many grass root
plants. Adoption of purge gas recovery plant to recover and recycle hydrogen
from the purge gas could result in increase in production by about 5% and simul-
taneously reduce energy consumption of the entire production by about 2%.
In a bulk drug plant, some reactions are carried out at very low temperatures
(around -80oC). Injection of liquid nitrogen is quite common for achieving such
low temperature in the industry. This method is rather inefficient and expensive.
Instead, a cascading type mechanical refrigeration system with R-23 and R-22/
R-717 in tandem can be considered for adoption to achieve the same temperature
at much lower investment and operating cost. Also the space requirement is less
for the refrigeration system. Adoption of cascading refrigeration system may bring
down the refrigeration cost by about 50% as compared to liquid nitrogen injec-
Process Engineering Channel

tion system for a given plant.

Use of aqueous calcium chloride brine was common in refrigeration. However,
numerous operating problems were experienced with it such as slimy spills,
chocking of pipelines due to freezing, difficulty in maintaining brine concentration,
etc. Aqueous monoethylene glycol (MEG) is found safe and convinient substitute
to aqueous calcium chloride brine, thereby design of brine circulation system is
simpified. Use of aqueous methanol brine is made for low temperature applications
@ProcessEng

(-20 to -50oC) but the brine solution is flammable in nature and requires specific
care in design. Thus adoption of new systems is a part of process intensification.
In large chemical plants, the network of heat exchangers can be reworked in
line with pinch technology (Sec. 6.13). Such an exercise can result in substantial
energy savings.
 Introduction to Process Engineering and Design

3.10 CONCLUSION

Process engineering is the heart of any process design. While adequate attention
at the design stage can pay rich dividends, adoption of process engineering prin-
ciples in a running plant is always paying.

Exercises

3.1 Give brief answers of the following.

(a) Name ten biofuels that are used for steam generation.
(b) Differentiate petroleum based lube oils and eco-friendly lube oils.
(c) An innovative hydrogenation process for edible oil is to be developed which is
based on supercritical principle. Carbon dioxide and propane are considered
as alternative supercritical fluids (SCFs) for the purpose. Study the advantages
and disadvantages of each for the purpose.
(d) Name five 'green' solvents for use in chemical synthesis.
(e) An aqueous Ao-propyl alcohol mixture, containing 50% alcohol (by mass), is
to be separated to a stream of 100% alcohol. Suggest process steps with rea-
sonings.
(f) Nitrogen stream at atmospheric pressure and dew point of -60oC is used for
deriming a cold box of air liquefaction plant. If argon is used instead of nitro-
gen, what should be the dew point on equivalent moisture content basis?
(g) For relatively small capacity storage of liquefied gases (such as ammonia, LPG,
etc.), a sphere construction is selected. Why?
(h) As a rule of thumb for most of the distillation cases, an increase in column
pressure means: (a) decrease or (b) increase in the column capacity and
(i) better or (ii) work fractionation, given other parameters.
(i) Opening stock of a fuel oil took was calculated as 600 kL x SG of 0.94 = 564
t, and the closing stock as 550 kL x SG of 0.94 = 517 t in a day, i.e. transfer of
47 t to the boiler. Temperature variations were ignored thinking that the varia-
tion in SG is about 1% and should, for all practical purposes, be acceptable. In
reality, the temperatures of the fuel oil at the time of measurements of opening
and closing stocks were such that corresponding SG were 0.94 and 0.95, re-
spectively. It really meant an error of about as much as (a) 5.5, (b) 3.5, (c) 1.5,
(d) 0.15 or (e) 0.05 t.
Process Engineering Channel

3.2 Chlorination of an organic compound is to be carried out with chlorine. Hydrogen

chloride gas with some chlorine are vented out from a batch reactor at near atmos-
pheric pressure. Consider the various options, available for trapping hydrogen chlo-
ride gas from the reactor and develop process flow diagrams for each of them.
3.3 Study a batch reactor operation. Write start-up, normal operating and shutdown
procedures for the reactor, including safety requirements. Also prepare a log-sheet
for the batch operation with a view to collect consolidated information for review
@ProcessEng

and comments.
3.4 In a chemical plant, a cooling tower of 1000 kW capacity is operated. An operator
reports in summer that the production is limited due to cooling tower. How will you
check the efficiency of the cooling tower?
 Process Engineering

3.5 In a batch reactor, reaction is carried out under reflux conditions for long hours
with a condenser using cooling water at 320C. Solvent used in the vessel is metha-
nol. Plant data indicate substantial loss of methanol to atmosphere during the reac-
tion. Analyze the situation and suggest remedial measures for loss prevention with
reasonings.

References

1. Jones, J., W. Asher, J. Bomben, D. Bomberger, C. Marynowski, R. Murray, R.

Phillips, D. Robers, K. Semaru, R. Swidler, C. Witham and J. Zuegel, Chem. Engg.,
100(4), April 1993, p. 138.
2. Lowenstein, T. G., Chem Engg., 92 (25), December 9, 1985, p. 62.
3. Frye, A. L., bid. Engg. Chem., 50 (4), 1958, p. 577.
4. Sharrat, P. N., Ed.. Handbook of Batch Process Design, Kluwer Academics, USA.
1999.
5. AIChExtra, Chem. Engg. Progr., 99 (9), 2003, p. 78.
6. Bhatt, B. I. and S. M. Vora, Stoichiometry, 4th Ed., Tata McGraw-Hill Publishing
Co. Ltd., New Delhi, 2004.
7. Kletz, T., Process Plants : A Handbook for Inherently Safer Design, Taylor and
Francis, USA, 1998.
8. Ludwing, E. E., Applied Process Design for Chemical and Petrochemical Plants,
Vol. 1-3, 3rd Ed., Gulf Publishing Co., USA, 1999-2001.
9. Elvers, B., S. Hawkins and G. Schulz, Ed., Ullmann's Encyclopedia of Industrial
Chemistry, 5lh Ed., Vol. B1 to B4, VCH Verlagsgesellschaft, Germany, 1988-1992.
10. McKetta, J. J. and A. W. Cunningham, Encyclopedia of Chemical Processing and
Design, Vol. 1 to 68, Marcel Dekker, Inc., USA, 1976-1999.
11. Evans, L., Jr., Equipment Design Handbook for Refineries and Chemical Plants,
Vol. 1 and 2, Gulf Publishing Co., USA, 1971.
Process Engineering Channel
@ProcessEng
 A
Chapter -_r

Importance of

Process Diagrams in

Process Engineering

4.1 INTRODUCTION

Engineering Diagrams are vital for understanding of a process to chemical engi-

neers, of equipments to mechanical engineers, of electrical circuits to electrical
engineers and so on. These diagrams are prepared in many different ways to suit
the specific requirements. Process Flow Diagrams (PFD) and Piping and Instru-
mentation Diagrams (P&1D) are basic requirements of process engineering and
are prepared before attempting any detailing. Steps followed in preparation of
these diagrams and interpretation of the same are covered in this chapter.

4.2 NEED FOR PFD AND P&ID

When any chemical manufacturing project is conceived, immediate information

is sought on the requirements of raw materials and utilities. This information can
be calculated using the Laws of Conservation of Mass and Energy, covered in
the previous chapter on Stoichiometry. When these data are presented in a
sequential manner with symbolic representation of equipments, it is known as
PROCESS FLOW DIAGRAM (PFD) or PROCESS FLOW SHEET. It can be
Process Engineering Channel

said that PFD is a schematic illustration of the system. It shows relationships

between the major components in the system. It also tabulates the process design
values for the components.
PIPING & INSTRUMENTATION DIAGRAM (P&ID) is different from PFD.
While PFD is a quantitative representation of the process, sequential presenta-
tion of flow, piping with instrumentation and controls that are required for smooth
operation of the process are given on a P&I diagram. It can therefore be said that
@ProcessEng

P&ID is a schematic illustration of functional relationship of piping, instrumen-

tation and system equipment components. It shows all the piping including the
physical sequence of branches, fittings, equipments, instrumentation and control
interlocks.
PFD is a useful diagram in effective communication of design information.
It helps an operator in adjusting his operating parameters, a shift supervisor in
 Importance of Process Diagrams in Process Engineering

checking the plant operation, management in discussions across the table and
project engineers in comparison and evaluation of different processes and their
quantitative requirements.
Modern plants have extensive instrumentation and controls such that a mini-
mum attention is required of an operator. Apart from controlling the plant vari-
ables, these plants give better productivity in terms of yield and quality. Also,
less manpower is required to operate the plant with increased safety.
Process engineers are involved in preparation of both these types of diagrams.

4.3 BLOCK DIAGRAMS

Simplest flowsheets are block diagrams. Process engineer begins the process
design with a block flow diagram in which only the feed and product streams are
identified. Such input-output diagrams are not very detailed and as such are most
useful in early stages of process development.
Figure 4.1 is a block diagram of the process to manufacture carbon dioxide
from flue gas of power generation plant using electrochemical membrane separa-
tion technique.
Absorption of carbon dioxide from the flue gas mixture using an aqueous
amine solution or caustic potash solution is difficult because of presence of oxy-
gen. Electrodialysis cell has an edge over the absorption technology in which
presence of oxygen is not a hinderence to the recovery of carbon dioxide. The
block diagram is useful in understanding overall process and also gives rough
quantitative picture of raw materials and utility consumptions. These data can
help in working out preliminary variable cost.
The processes, described in the block diagram, are then broken down into
basic functional elements such as reaction and separation sections. Process engi-
neer can also identify the recycle streams and additional unit operations to achieve
the desired operating conditions. Identification of basic elements help in per-
forming material and energy balance calculations which in turn help in prepara-
tion of the PFD.

4.4 DEVELOPMENT AND UTILITY OF PROCESS FLOW

DIAGRAMS
Process Engineering Channel

Any product or process development starts with stoichiometric calculations. At

first, required capacity of the final product is fixed. The product can normally be
manufactured by inputting different raw materials and following different proc-
ess routes. For example, manufacture of ammonia is possible with different hy-
drocarbon feed stocks such as natural gas, naphtha, fuel oil, coal, etc. Process
route for each feed stock is different. For example, reforming is a preferred route
@ProcessEng

for natural gas or naphtha while partial oxidation is the route followed for fuel
oil or coal. Nitrogen for the ammonia manufacture is invariably obtained from air
but it may be fed as air or nitrogen is separated from air by liquefaction and it is
fed to the process. PFD (Process Flow Diagram) for each continuous process is
different.
 56 Introduction to Process Engineering and Design

Natural Gas Feed

Ambient Flue Gas from

Air Feed Electric Power Power Generating
'W >
Output > 30 MW Utility
2600 t/d
9% C02(v/v)
150oC

Electrochemical 270 t/d

C02
Membrane Product
0
16Q C Separation
Separation and
720 C IITA = 121 m2 Liquefaction
Anode
Membrane Liquid
Cathode C02
Feed
Power in = 5.2 MW 720oC 200 t/d
Preheat

2667 t/d
Exhaust He
Electrochemical 2 Exhaust
Cell Feed HTA = Gas to
2936 t/d 2325 m2 02 Recycle Atmosphere
8.5 % C02 (v/v) 70 t/d 210oC
Hot Flue
3.8 % 02 (v/v) Gas 130oC
650oC 600oC

Auxiliary
Furnace
3 MW Heating Air Feed at 10oC
260 t/d
Natural Gas Feed at 10oC
t
Process Engineering Channel

7 t/d
Fig. 4.1 Block Diagram for Manufacture of 200 t/d C02 by Electrochemical Membrane Process1
(Reproduced with the Permission American Institute of Chemical Engineers, USA)

Another example is reduction of nilro aromatic compounds to corresponding

amines. In a classical Bechamp process, nitro compound is mixed with water and
fine iron powder in a batch reactor. The reaction mixture is moderately healed in
@ProcessEng

presence of a catalyst to initiate the reaction (basically in an acidic medium).

Hydrogen is generated in situ and reduces the nitro compound to corresponding
amine. Reaction is exothermic and temperature is controlled by cooling. Reac-
tion takes long time to complete. Product mixture is separated in organic and
aqueous layers. While aqueous layer is drained out, organic layer is siphoned and
purified by filtration and distillation under vacuum.
 Importance of Process Diagrams in Process Engineering

In newer version of the process, hydrogen gas is bubbled in the organic liquid
under pressure. Nickel or noble metal based catalyst is used. Gas dispersion
through the liquid is improved by different methods such as use of static mixer,
use of gas induced agitator, liquid jet ejector system, etc. Such a system is quite
efficient and the reaction can be completed in relatively short period. Both the
process routes are used in industry. PFDs for both the routes are different.
Above examples involve chemical reactions. However, there are PFDs which
involve unit operations but no chemical reactions. For example, separation of
components of natural gas in a distillation column by cryogenic means, removal
of acid gas by absorption-desorption, removal of Volatile Organic Compounds
(VOC) by adsorption-desorption, etc., do not involve a chemical reaction. Each
PFD is, therefore, to be treated on its own requirements.
A Process Flow Diagram generally includes following information.
(a) Flow rate of each stream in case of continuous process or quantity of each
reactant in case of a batch process.
(b) Composition of streams.
(c) Operating conditions of each stream such as pressure, temperature, con-
centrations, etc.
(d) Heat added or removed in a particular equipment.
(e) Flows of utilities such as steam, cooling water, brine, hot oil, chilled water,
thermic fluid, etc.
(f) Major equipment symbols, names and identification.
(g) Any specific information which is useful in understanding the process. For
example, symbolic presentation of a hazard, safety precautions, sequence
of flow, etc.
PFD of a laboratory scale process could be somewhat different from that of
plant scale PFD. In laboratory, more emphasis is given on safety aspects. Also
some utilities could be different from those used on a plant scale. For example, in
laboratory use of ice and dry ice are common for achieving required chilling. On
a plant scale, chilled water or chilled brine at different temperatures are used.
Similarly, once through raw water system is common for cooling in condensers
in the laboratory while closed circuit of cooling water is a practice in the industry.
Batch distillation is commonly employed in the laboratory while in plants, batch
Process Engineering Channel

or continuous distillation columns are employed with specific controls to achieve

desired purity of the distilled materials.
Process Flow Diagram of a laboratory experimental unit could be simple and
different from that of a pilot plant. Thodos et at have described a PFD for the
study of reaction kinetics to synthesize ethyl chloride from ethylene and hydro-
gen chloride gas. This is a gas phase endothermic catalytic reaction, studied in
the pressure range of 8-11.5 bar a and temperature range of 150oC-300oC. A
@ProcessEng

100 mm steel pipe reactor with electric heating element, wrapped over it, was
used. Dry ice trap, following the reactor, removed ethyl chloride while excess
HC1 was scrubbed in a water trap. Thus a continuous experimental set-up pro-
vided useful data for determining reaction rate equation.
When the above process is to be studied on a pilot plant, the reactor could still
be a pipe (bigger in size) with jacket in which thermic fluid (hot oil) circulation is
 Introduction to Process Engineering and Design

provided. For separation of ethyl chloride, heat exchanger with chilled brine can
be considered. Scrubbing of unreacted HC1 can be performed in an efficient packed
tower.
Prugh has developed a laboratory scale PFD for the manufacture of phenylethyl
alcohol by reacting ethylene oxide and benzene in presence of aluminium chlo-
ride catalyst. Such a PFD is helpful in transferring information from the research
chemist to the process engineer, engaged in designing a pilot plant or in develop-
ing a PFD for a commercial plant. Sufficient stress is laid on safe scale-up.
Effectiveness of the research efforts is thereby improved in designing a plant.
In the laboratory, many hazardous reactions are carried out such as chlorina-
tion, hydrogenation, ozonation etc. Some of them are not only explosive but also
prone to health hazards. During scale-up of such processes, these aspects need
special attention so that the plant is safe in operation and environmental pollution
problem is not created. For example, venting of hydrogen containing gas mixture
must ensure that the gas mixture is outside flammability limits. Also a right type
of flame arrestor is to be installed on the vent. Similarly chlorine to be vented is
to be scrubbed in aqueous caustic solution. These details form a part of process
(although not a part of reaction) and therefore PFD must include these equipments.
PFD of a commercial plant covers material and energy balance details exten-
sively. In PFDs of batch processes, quantities of inputs and outputs are specified
with normal operating conditions. For a continuous process plant, a good prac-
tice is to give process stream flow rates and compositions in a tabular form at the
bottom of PFD. Reference 4 gives several PFDs for batch as well as continuous
processes.
Development of PFD of a process plant starts with conceptual design. At first
the process flow sequence is established with the help of symbols of equipments
or blocks. While symbols of equipments give better idea of the type of equip-
ment to be deployed, block diagrams are satisfactory to start with. End product
and capacity of production are defined which are entered at the end of PFD. Then
an overall theoretical material balance is established to find the theoretical raw
materials requirements. These quantities are entered at appropriate places in PFD
where the specific raw materials are to be introduced. Thus a preliminary PFD is
prepared. Now start establishing material balance and energy balance across each
equipment taking into conversion limitations, catalyst activity, equipment limita-
Process Engineering Channel

tions, etc. It is well known that conversions are dictated by kinetic considerations
and hence it is not possible to achieve 100% conversion every time. These calcu-
lations are performed for each equipment with actual conversions and results are
entered in the PFD. With these revised data, PFD becomes more like a working
PFD. To this, add utilities and safety aspects. Final PFD is now ready for
presentation.
@ProcessEng

Material and energy balance calculations for the manufacture of formalde-

hyde from methanol based on Formox process are well covered in Ref. 4. Using
this information, its PFD is developed for a plant having methanol feed rate of
4000 kg/h (Fig. 4.2). In this diagram, process flow rates and operating condi-
tions are given along the process lines. Heat duties of various equipments are
also specified near the respective equipment. Stream compositions are given in
tabular form at the bottom of the PFD.
 Importance of Process Diagrams in Process Engineering

The above PFD is quite useful to a process engineer in detail design of the
equipments, selection of right equipment for the duty, pipe sizing, selection of
right instrumentation and control system, etc. Further, PFDs, submitted by dif-
ferent vendors at the quotation stage, help the project engineer in comparison
and evaluation of alternative process routes. Competitive processes can be evalu-
ated from different angles such as ease of operation, minimum energy require-
ment, less hazardous operation, etc. Such an evaluation becomes useful in dis-
cussions with the management across the table thereby the technologically best
plant can be selected.
PFD of an operating plant provides design data at 100% plant load. Such a
diagram helps the operator in adjusting his process parameters and the shift su-
pervisor in checking/controlling the plant operation to optimize the production.
Manufacture of formaldehyde is a catalytic process. Comparison of actual oper-
ating data with the design conditions (such as those given is Fig. 4.2) can provide
a trend analysis thereby a decision can be taken on when to change the catalyst.
However, if the supervisor finds that productivity of the plant is not commensu-
rate with the anticipated catalyst life he would look for other factors like poisioning
of catalyst, fouling of coolers, etc. responsible for the same and corrective
actions can be taken.
In Fig 4.3, PFD for the production of liquid oxygen from air at low pressure
(~ 10 bar g) is given. In this process only physical separation takes place unlike
chemical reaction, described in Fig. 4.2. This PFD was developed to compare the
low pressure process with the high pressure (~ 135-140 bar g) process. It does
not give the process flows and stream compositions and hence it is not directly
useful to plant operating personnel. Neverthless it is useful to the project engi-
neer in preliminary evaluation.
PFD of a utility system is somewhat different from the PFD of the process
plant. Steam generation, steam distribution and utilization, cooling water circuit,
thermic fluid circuit, instrument/plant air system, nitrogen (inert) gas system,
refrigeration system, etc. fall under this category. Figure 4.4 is a typical cascade
steam balance of a large chemical plant. This is also a PFD of the steam system.
Development of an efficient steam system can pay rich dividends in terms of
optimum energy input.
Process Engineering Channel

In Ref. 4, several steam balances are worked out for the same plant and
corresponding PFDs are presented to exemplify the alternatives available to a
process engineer during the design stage.
Similar PFDs can be developed for other utility systems. Liu et af1 have pre-
sented PFDs for raw water in a chemical plant. Reduction in raw water consump-
tion as much as 50% could be achieved by optimizing such a PFD.
Cooling water is yet another utility for which an efficient distribution network
@ProcessEng

can be developed. In Fig. 4.7, cooling water network is demonstrated.

Process flowsheeting can be carried out with the help of a computer. Steady
state material and energy balance calculations can be performed on a spreadsheet
or with the help of mathematical software which also can generate block diagrams.
Specialized software such as Microsoft Visio, Aspen Plus, etc. are available for
 Introduction to Process Engineering and Design

55 100 165 300

Fuel 100 bar g 440oC

— ^ Auxiliary Boiler
110 200 Furnace 12 675 kW
315 C Superheater 22 600

41.4 bar g 3430C

Steam
H-n Drum
"i—
Waste Heal F T-2 T-3 -4 T-5 r-6 Process
Exchangers Ileaters
1120 kW 670 kW 820 kW 3355 kW 12675 kW
Slowdown 8.5 bar g
1 Flash Drum 25 000 I XI) S3 600
+1800 CWR
T-7 Steam Process Process
10801 Jet Feed Healers
320 2.4 bar g 150 kW Ejccto —I
Surface
Furnace 600 Condenser
Economizer CWS
I 360
Process
154 420 Heaters Condensate
(I Dcacralor Flash Drum
[^62100 0.7 bar g 1I5.50C i r . p 3900 kW
I 133 080 Condensate Pumps _/^\. 107 000
^820 kW 7^. y
\ 7 Condensate
Boiler Feed Process
Water Pumps Heat Recovery Extraction Pumps
26 080
Boiler Feed Make-up Water55
Note: All flows are in kg/h
Fig. 4.4 Steam Balance in a Large Chemical Plant6 (Reproduced with the Permission from Chemical
Engineering by Access Intelligence. USA)

the preparations of PFDs. References 8-10 are useful in developing computerized

flow sheets.

4.5 DEVELOPMENT OF PIPING AND INSTRUMENTATION

DIAGRAMS

Having understood the requirements of PFD, it is rather easy to understand the

requirements of P&ID. Emphasis is changed from process flows to process con-
trol. Controls are not possible without measurements of variables; such as pres-
sure, temperature, concentration, etc. for which instruments are required. A dia-
Process Engineering Channel

gram incorporating piping, instruments and controls is known as P&ID.

In simple plants minimum instruments are installed. They are just adequate
for manual control. However, it is needless to emphasize that installation of ad-
equate instruments justify the cost in terms of productivity and safely. Many batch
processes are being controlled in manual manner. But as the scale of plant is
getting bigger and bigger, role of instrumentation and control (I&C) is becoming
@ProcessEng

important. This I&C hardware not only results in smoother and efficient plant
operation but also gives safer operation and high onstreams factor. Modern chemi-
cal plants incorporate sophisticated I&C, thereby centralized operation from a
control room is possible. PLC (Programmable Logic Control) and DCS (Distrib-
uted Control System) have become common terminology in I&C. Touch screen
operation of the panel gives a wealth of information to the operator at his finger
tips.
 Importance of Process Diagrams in Process Engineering

In addition to I&C, P&ID also incorporates other details such as pipeline de-
tails, location of valves and fittings, safety valves' locations, etc. In major chemical
engineering projects, piping and fittings are classified to cover specific range of
pressure and temperature for each fluid. This classification lists material of con-
struction, thickness, types of fittings required, etc. for piping. This classification
is mentioned on each pipe symbol on P&ID in addition to the size of the pipe.
Many times, fluid flowing in the pipe, is indicated by symbolic letters; e.g. NG
for natural gas, S for steam, etc. This helps project engineer to specify the piping
material with fittings for procurement with ease.
Apart from instrumentation and control details, many other details are also
covered on P&ID. Cold and hot insulation are marked. At times elevation is
mentioned when relative height of a specific equipment is important. For exam-
ple, barometric condenser is installed at 10.5 m height from hotwell water level
as standard atmospheric pressure equals 10.33 metres of water column. Simi-
larly, when a pump take suction from a vacuum system, NPSH requirements are
to be met which means positive suction is required depending on the vacuum.
Deaerator for boiler feed water (BFW) is installed at a height to provide suffi-
cient NPSH to BFW pump. When complete draining of a vessel is desired, slope
of specific pipeline is desired which can be indicated on P&ID in a symbolic
manner. Man-entry and maintenance requirements are kept in mind while prepar-
ing P&ID. For this purpose, purging of vessels with inert gas/compressed air is
necessary although this requirement is not indicated on PFD. Location of sample
point and their arrangements are also shown on P&ID.
Symbolic presentation on the diagram should be easily understood by the en-
gineer. There are standard symbols for such presentation. All engineering com-
panies have their own standard symbols which are supplied alongwith P&ID.
However, standards are prevalent for the graphical symbols. Among them,
following are prominently followed by many.
Indian Standards:
IS: 3232 Graphical Symbols for Process Flow Diagrams
IS: 9446 Graphical Symbols for Pipelines and Instrumentation Diagrams
US Standards:
ANSI Y32.2.3 Graphical Symbols for Pipe Fittings, Valves and Piping
Process Engineering Channel

ANSI Y32.2.11 Graphical Symbols for Process Flow Diagrams

ISA 5.5 Graphical Symbols for Process Displays
British Standards:
BS: 1646 1 to 4 Symbolic Representation for Process Measurement, Control
Functions and Instrumentation
German Standards:
@ProcessEng

DIN 19227 PI to P3 Graphical Symbols and Identifying Letters for Process

Measurement and Control Functions
Figures 4.5 (a) and (b) give recommended symbols for equipments while
Figs 4.6 (a) to (c) give recommended symbols for piping, instruments and con-
trols which will be generally followed in this book.
Bartow el aln have presented a P&ID for a pilot plant to carry out research
and development work relating to manufacture active pharmaceutical ingredients
 62 Introduction to Process Engineering and Design

not
TT Plate Heat
Dryer Spray Heat Exchanger (Kettle Type Reboiler) Exchanger

Or )
, I
Ejector (for Gases) n
Or
Eductor (for Liquids) Heat Exchanger (Shell and Tube Type) Packed Tower

A
ZD
d —»■
Heat Exchanger
Spray Type
Fuel Fired Furnace (Serpentine Cooler)
Or Tray Tower
I

Screen Spray Tower

Flaker Hopper

■..I'
Air Cooled Atmospheric Tank t
Heat Exchanger Mixer (Cone Roof) Silencer

Stm

)
Condi
Bayonet Type Pressure Storage
Floting Roof Tank
Heat Exchanger Mist Eliminator (Mesh) ( Sphere or Spheroid )
0
Process Engineering Channel

I
Basket Filter Duplex Filter Self Cleaning Vertica Centrifugal
(Valve Integral) Filter Pump
M M

-M- -H- C J
Sight Glass Self Cleaning Filter Submercible Pump
@ProcessEng

Stack (with Indicator) (Motor Operated) (Sump Pump)

IIIlIII
-Ano
A C.
I
Flame Strainer Heating or Rotary Pump or
Arrestor Temporary Cooling Coil Compreser
Fig. 4.5(a) Symbols for Equipments
 Importance of Process Diagrams in Process Engineering 63

Flanged End
>-0
Coupling End Or

t 0r Centrifugal pump
Hoses Separator
(Steam, Oil or Water) Sight Glass Plain Or compressor

Or
M H
Compressor or
Couplings Plain Motor Positive Rotary Pump
Catalytic Reactor

T->-
u
Safety Reciprocating
Pneumatic Conveyor Jacketed Vessel Shower Compressor or Pump

-ooooooo-

Belt Conveyor Bellow Perforated Pipe Agitator (Turbine)

Open Rotary TV
Roller Conveyor Weigh Scale
Vacuum Filter Bag Dust Collector

T I
Rotary Feeder Crusher Autoclave Drain Point (Closed)

ill I
Process Engineering Channel

Turbine
(Steam, Gas or Mechanical Stirrer
Cooling Tower Rotary Dryer Hydraulic)
CWS i
Gas Out
Gas In AAAA/V'u% JA
0 cwr
@ProcessEng

Spray Cooler Screw Conveyor Eye Wash

Conveyor (Bucket) (Barometeric Condenser) or Static Mixer Fountain

Gear Pump Hot Flare Cold Flare Horizontal Tank

Fig. 4.5(b) Symbols for Equipments
 Introduction to Process Engineering and Design

IX] Gate Valve Butt Welded Diaphragm Operated

—ICXI— Gate Valve Flanged 1® Butterfly Valve
0
Electric Motor
Dcc3 Globe Valve Butt Welded —1X1— Operated Valve

—D>5— Plug Valve Flush Bottom Tank Valve

¥
Three Way Plug Valve —— Nccddlc Valve

— Ball Valve Direct Float

—
Operated Valve
Angle Valve Piston Operated Valve
( Air or Oil)

—ixl— Damper Valve Pressure Reducing Valve

—£5— Diaphragm Valve 01^- Slide Valve

Butterfly Valve (a) izja (b) 't' Rupture Disc

—
(a) In Line, (b) On Line

Air Motor Operated Valve —>1X1— Hose Connection

—t5}—

-rr^y- Vent or Drain

Bellows Seal Valve —>1X11 With Blind

Combination of Safety Relief Y-Type Strainer

1
Valve & Rupture Disc Assy N1 '
Safety Relief Valve with *4 Valve Closed
— Hand Lever

—ft— Control Valve X—] Vent or Drain Plugged

Diaphragm Operated OR-^ Check (Non-Return)

^h- Control Valve Valve
—rxh-
Diaphragm Operated Valve Solenoid Operated
(Angle Type) —cS— Gate Valve
Diaphragm Operated Solenoid Operated
Control Valve Gate Valve with
(Three Way Type) —
Manual Reset
Process Engineering Channel

Main Line Spectacle Blind

(Normally Closed)

Auxiliary Line Spectacle Blind

(Normally Open)

Piping Under Ground \/ Drain

Insulated Piping 1 Trap Assembly

—
@ProcessEng

Jacketed Piping Restriction Orifice

and Flange

Tracing (Process) Union

Fig. 4.6(a) Symbols for Piping

 Importance of Process Diagrams in Process Engineering

Electrically Traced Piping Reducer (concentric)

—

OR Piping Crossover —ti— Reducer (eccentric)

1
Piping Junctions (distinguished Elbow 90°
from Crossover by Displacement) Short Radius (R = I D)
Flow Direction (Arrows at Elbow 90°
(aO (b)\ Long Radius (R =1.5 D)
Change at Routing) (a) Butt Weld (b) Screwed/sw

Piping Flange Elbow 45°

/ Screwed or Socket Welded
Alteration in Pipe Size (only
II Piping Flanged with Blind Shown where Esseantial to
Understand Process Requirement)

& Pipe Termination with Cap/BW Self Actuated Control Valve

——
Pipe Termination with Piping Identification (Typical)
3 Screwed/SW Example: S-3-100-CS1
// \V
—>4— Steam / \ Piping Specifications
OR < i > Pipe Specification Change
Number Pipe Size
Owner Note: Process engineer can develop his own
Boundary by Indication piping identification.
(suitably Closed)
Contractor

Fig. 4.6(a) Symbols for Piping

A. Instruments

—H|l—
Orifice Meter Venturi Meter Gauge (Pressure or
Temperature)
H!h
Y
u u

Rotametcr Bypass Rotametcr

-Mool—>-
Process Engineering Channel

Level Gauge Turbine Flow Meter

B. Instruments Signal Lines
Pneumatic (Air) Signal
Electric Singal
Instrument Impulse Line
@ProcessEng

—X— Instrument Capillary Tube

Radioactive, Sonic or Light Signal
E/P Potential to Pneumatic Converter
I/P Current to Pneumatic Converter
E/I Potential to Current Converter

Fig. 4.6(b) Symbols for Instrumentation and Controls

 Introduction to Process Engineering and Design

C. Instrumentation Symbols
Locally Mounted Instrument

Main Panel Mounted Instrument

Local Panel Mounted Instrument

F. Common Service Fluid Codes

Instrument Mounted Behind Panel
Instrument Air IA
Plant Air PA
Process Air PRA
( I h Instrument with Two Functions Fuel Gas FG
Inert Gas/Nitrogen IG/N
-V
function Vent V
Blow Down BD
wwWj Instrument Identification Effluent EFF
ProcessV Y^yW Special
Variable Drain DR
Insirumcnl RW
Number Raw Water
Examples Demineralized Water DMW
Process Water PW
w
Pressure Indicating Controller Cooling Water CW
<i) No. 51 Hot Water HW
Chilled Water CHW
High and Low Temperature Alarms
Brine BR
Steam S
(C) S NH High and Low Level Alarms R
Refrigerant
— LA and HO
Hot Oil
Low Low Level Trip
Trip
Air Main Panel Mounted Analyser Indicator
(d)
and Recorder for Oxygen

Common Symbols
D. Process Variable Symbols
Pressure P
Process Engineering Channel

Temperature T
Flow F
Level L
Analysis A
Ratio R
E. Instrument Function Symbols
Indicator I Element E
Controller C Gange G
Alarm A Well W
Differential D Recorder R
@ProcessEng

Fig. 4.6(c) Symbols for Instrumentation and Controls

(API) in a bulk drug plant. Different types of reactions can be carried out in
such a pilot plant with heating and cooling, varying form cryogenic conditions
(upto -100oC) to hot conditions (upto +250oC). Process engineer can develop
P&ID for such an universal facility.
 Importance of Process Diagrams in Process Engineering

Figure 4.7 is P&1D for formaldehyde manufacturing, described in Fig. 4.2

with recycle option. It is developed to ensure safe and smooth operation of the
plant in an efficient manner.
Types of control system, shown in Fig. 4.7 can vary from one process engineer
to another. For example, air flow to the reactor can be controlled by a control
valve on feed air line (A-3-750-CS1). However, in Fig. 4.7, vent controls the feed
air flow. Such a control system is found more reliable and accurate in industries.
Also, discharge pressure of the blower could be lower in the suggested scheme.
Flow of demineralised (DM) water to the absorber may not be a critical require-
ment. Manual control could therefore be adequate and costly I&C system for its
flow control may not be warranted. Thus, preparation of P&ID provides an op-
portunity to the process engineer to demonstrate his skills. Further, the diagram
has to take care of start-up requirements, emergency response, purging, etc.
In certain plants, universal facilities are required for the manufacture or process-
ing of similar products. For example, manufacture of different amino and alkyd
resins call for such an universal facility. Lanson12 has presented a P&ID for the
resin manufacturing either by azeotropic distillation process or by vacuum proc-
ess. An edible oil refinery in which edible oils of different seeds can be refined
also represents a similar case.
Several softwares are available for preparation of P&ID also. Microsoft Visio,
Aspen Plus, Smart Sketch, etc. can be used to reduce the time in such prepara-
tion.

4.6 CONCLUSION

PFD and P&ID are indispensable as transmitters of information, essential in the

design stages. They can also be considered as the instruments of communication.
In the final analysis, process diagrams communicate an astonishing amount of
engineering information about many things to many groups for a variety of uses.
It is not surprising that preparations of PFD and P&ID have assumed great
importance in chemical process industry. Process engineers can produce innovative
designs which can be well presented by these diagrams. Time spent on preparation
can easily result in cost savings, efficient plant layout and safer plant operation.
Process Engineering Channel

Exercises

4.1 Prepare P&l diagrams for following cases with safety measures.
(a) Hydrogen from a bullet at 10 bar g and 40oC is let down to 2 bar g for feeding
to edible hydrogenation reactor.
(b) Carbon dioxide is to be cooled from 110oC to 4()0C using cooling water in an
@ProcessEng

intercooler at 68 bar a. Cooling water is supplied at 320C. Critical pressure and

critical temperature of carbon dioxide are 73.77 bar and 310C, respectively.
(c) A heat sensitive product is concentrated in a wiped film evaporator (refer Chap-
ter 8) at absolute pressure of 1 x 10"3 Pa and 180oC. Ultra high vacuum is
achieved with the help of dry vacuum pump and 3-stage ejector system (with
 Introduction to Process Engineering and Design

barometric condenser) in series. A cold trap is provided with brine/steam utili-

ties for knocking off organic vapours, being carried to the vacuum system.
Temperature in the evaporator is controlled by thermic fluid, entering at 240oC
in the jacket and leaving at 220oC from the jacket. Adequate instrumentation
and controls are to be provided for smooth operation.
(d) Visit a nearby liquefied gas (such as ammonia, carbon dioxide, LPG, etc.) stor-
age facility, study the same and prepare a P&I diagram of the system, including
storage tank and holding refrigeration system.
4.2 A pilot plant reactor (SS 316L) of 250 L geometric capacity is to be designed for
conducting sponsored research at any temperature, ranging from -80oC to -i-220oC.
For this purpose, it is desired to use a specialty synthetic (silicone polymer based)
heat transfer medium, such as Syltherm XLT® of Dow Chemical Co., USA. Typical
properties of Syltherm XLT are as under.
Chemical: Dimethyl polysiloxane
Average molar mass: 317
Flash point: 540C
Auto ignition temperature: 350oC
Freezing point: Less than -110oC
Density @ 250C: 0.852 kg/L
Gross heat of combustion at 250C: 32 800 kJ/kg
The reactor will be suitable for maximum operating pressure of 25 bar g. It will
be provided with a turbine agitator with a variable speed drive for speed control in
the range, 80-200 rpm. A flame proof electric motor of 3 kW capacity, operating on
415 ± 10% V, 3 phase, 50 ± 2 Hz power will be used as a drive. Agitator will be
sealed with a mechanical seal with cooling arrangement with cooling water circula-
tion.
The reactor will also be suitable for operation under vacuum upto 700 ton-. Re-
flux arrangement with two condensers; one using cooling water at 320C and an-
other vent condenser, using brine at -l 0oC, will be provided.
Heat transfer medium (HTM) will be circulated in the jacket with the help of a
gear pump. A degassing tank of 100 L capacity will be provided at 2 m elevation
relative to the outlet nozzle of the reactor.
(a) HTM will be cooled from -40oC to -100oC with liquid nitrogen in a welded
plate heat exchanger (PHE).
Process Engineering Channel

(b) HTM will be cooled with the help of refrigerant R-22 in the temperature range
-40oC and +40oC in a welded PHE.
(c) HTM will be cooled with cooling water at 320C in the temperature range +40oC
and +80oC in a shell and tube heat exchanger.
(d) HTM will be heated upto +160oC with saturated steam at 7 bar g in a shell and
tube heat exchanger.
(e) HTM will be heated beyond +160oC upto +220oC with the help of thermic
@ProcessEng

fluid, supplied at +280oC in a shell and tube heat exchanger.

Heat transfer duty will be 5 kW for each case.
Based on above information, develop a P&I diagram of the above system.
4.3 Prepare a PFD for the manufacture of nitric acid based on stoichiometric calcula-
tions, given in Examples 2.9 and 2.10.
 Importance of Process Diagrams in Process Engineering

References

1. Winnick, J., Chem. Engg. Prog. 86 (1), 1990, p. 41.

2. Thodos, G. and L. F. Stutzman, Ind. Engg. C/tem., 50 (3), 1958, p. 413.
3. Prugh, R. W., Chem. Engg. Prog., 70 (11), 1974, p. 72.
4. Bhatt, B. I. and S. M. Vora, Stoichiometry, 4lh Ed., Tata McGraw-Hill Publishing
Co. Ltd., New Delhi, 2004.
5. Guccione, E., Chem. Engg., 72 (4), 1965, p. 144.
6. Slack, J. B., Chem. Engg., 79 (20), 1972, p. 107.
7. Liu, Y. A., B. Lucas and J. Mann. Chem. Engg., Ill (1), Jan. 2004, p. 30.
8. Westerburg, A.W., H. P. Hutchison, R. L. Motard, P. Winter, Process Flowsheeting,
Cambridge University Press, UK, 1980.
9. Turner, J., Chem. Engg. Progr., 88 (8), 1992, p. 59.
10. Julian. F.M., Chem. Engg. Progr., 81 (9), 1985. p. 35.
11. Bartow, M. and E. Spark, Chem. Engg., Ill (1), Jan. 2004, p. 49.
12. Swaraj Paul, Surface Coating; Science & Technology, 2nd Ed., John Wiley & Sons,
USA, 1985, p. 127.
Process Engineering Channel
@ProcessEng
 Chapter
D

Process Design

of Piping, Fluid

Moving Devices

and Flow Meters

5.1 INTRODUCTION

A fluid is a substance which when in static equilibrium cannot sustain tangential

or shear forces. This property of action under stress distinguishes it from the
'solid' state of the matter. Fluids are commonly divided into two substances;
liquids and gases. A liquid occupies a definite volume, indepedent of the dimen-
sions of its container while a gas tends to expand to fill any container in which it
is contained. A vapour differs from a gas by being readily condensable to a liquid
on cooling.
Striclty speaking all fluids are compressible. However, gases are frequently
regarded as compressible while liquids are as incompressible as the latter under-
goes small changes in the properties under compression. Ambient air is treated as
incompressible fluid as its density changes insignificantly with minor changes in
atmospheric pressure and temperature. When compressed, air is treated as a com-
pressible fluid.
In a pump, a fan or a compressor, mechanical work is transformed into fluid
Process Engineering Channel

enegry. A turbine is a machine for transforming fluid energy into mechanical

work at the rotating shaft. The word 'pump' is normally used for a machine
handling liquid. In a fan the density change is so small, due to realtively low
pressure difference, that the gas is regarded as incompressible for evaluation. In
a compressor, the density change is appreciable.
This chapter deals with fluids, its transportation through various moving devices
@ProcessEng

and various flow measuring instruments.

5.2 PROCESS DESIGN OF PIPING

Design of piping system incorporates all major disciplines of engineering like

chemical engineering, mechanical engineering, civil engineering, instrumentation
and control engineering, electrical engineering, etc.
 Process Design of Piping, Fluid Moving Devices and Flow Meters

Process design of pipe is a balance between size or diameter of pipe and pres-
sure drop in the pipe. For a given flow rate of fluid if larger size of pipe is se-
lected then it gives lesser pressure drop. Larger size of pipe increases the fixed
cost of pipe and lesser pressure drop means lesser power consumption or lesser
operating cost of pipe. Lesser pressure drop in pipe may reduce the size of flow
moving device like pump and thereby it may reduce the fixed cost of pump. Thus
capital cost of pipe increases with diameter, whereas pumping or compression
cost decrease with increasing diameter. Ideally one should find the pipe size which
gives the sum of amortized capital cost plus operating cost a minimum or one
should find the optimum pipe size.

5.2.1 Optimum Pipe Size

Several equations and nomographs are available to estimate the optimum pipe
diameter. But these equations or nomographs are not reliable as optimum pipe
diameter depends on the current cost of material, cost of power, rate of interest at
particular place and at particular time. It changes with place and time. For exam-
ple, optimum pipe diameter equation, derived in USA, cannot be used to find the
same in India. One such equation1 derived for carbon steel pipe and turbulent
flow is
J0p. = 293 G (5.1)
where, dopx = Optimum pipe size, mm
G = Flow rate, kg/s
p = Density of fluid, kg/m3

5.2.2 Recommended Fluid Velocities in Pipe

The velocities, recommended in Table 5.1, are only for approximate calculations
of pipe diameter which can be used for the quick calculation of short distance
pipe line or for estimating pipe size as a starting point for pressure drop calcula-
tions.

5.2.3 Pressure Drop in Pipe

Process Engineering Channel

Relation between pressure drop and pipe diameter is given by Fanning or Darcy
equation. It is derived for steady flow in uniform circular pipes running full of
liquid under isothermal conditions.

Ap 2/ v2 p 32/G2
(5.2)
@ProcessEng

L 2
8c Di 7t pgcDf

For SI units, gc = Newton's law conversion factor = 1

where, Ap = Pressure drop, Pa
L = Length of pipe, m
 Introduction to Process Engineering and Design

G = Mass flow rate of fluid, kg/s

p = Density of fluid, kg/m3
D, = Pipe inside diameter, m
v = Velocity of fluide, m/s
/= Fanning friction factor

Table 5.1 Recommended Fluid Velocities

Fluid Recommended Velocity, m/s

Water Pump suction line 0.3 to 1.5
Pump discharge line 2 to 3
Average service 1 to 2.5
Steam 0 to 2 atm g, saturated 20 to 30
2 to 10 atm g, saturated 30 to 50
Superheated below 10 atm g 20 to 50
Superheated above 10 atm g 30 to 75
Vacuum lines 100 to 125
Air 0 to 2 atm g 20
> 2 atm g or above 30
Ammonia Liquid 1.8
Gas 30
Organic liquids and oils 1.8 to 2
Natural gas 25 to 35
Chlorine Liquid 1.5
Gas 10 to 25
Hydrochloric acid Liquid 1.5
Gas 10
Inorganic liquids 1.2 to 1.8
Gas and vapours 15 to 30

The Fanning friction factor is a function of the Reynolds number (Re) and the
roughness of inside surface (£).
Values of £ for various materials are given in Table 5.2.
Process Engineering Channel

Table 5.2 Values of Surface Roughness for Various Materials

Material Surface Roughness e, mm

Commercial steel or Wrought iron 0.045 72

Galvanized iron 0.152
Cast iron 0.259
@ProcessEng

Concrete 0.305 - 3.05

Riveted steel 0.914-9.14
Brass, Lead, Glass, Cement and Bituminus Linings 0.001 524
 Process Design of Piping, Fluid Moving Devices and Flow Meters 73

A plot of fanning friction factor as a function of Reynolds number {Re) and rela-
tive roughness, e/D is given as Fig. 5.1.

(e®/) o.o?
—r 0.04
0.015 OJOB
0.02
v 0.015
0,01 Oam
0.008 01X06
0.004
0.006 0.002
0.0006
0.005 0.001
D
0.004
0.0002
0.003 0.0001
')) 0,00005
0.0025 ""th
'uhf.V
0.002
30
0.0015

0.001
2 3 45 7 2 3 45 7 2 3 45 7 2 3 45 7 2 3 45 7
1 x I03 1 x 104 1 x 10- I x 106 1 x 107 1 x 108

Reynolds Number. Re

Fig. 5.1 Fanning Friction Factors2

(Reproduced with the Permission of McGraw-Hill Education, USA)

For turbulent flow in commercial steel pipe, /= 0.0394 Re-0 16

(5.3a)
Above equation gives the value/on higher (safe) side. One of the more accurate
relationships between/and Re for turbulent flow (Ref.: 3)

1 Re
= -1.7372 In (5.3b)
1.964 ln(/?e) - 3.8215
V7
Process Engineering Channel

DjVp 4G
where, Re = (5.4)
p KD, jd

p = Viscosity of fluid
From Eqs. (5.2), (5.3a) and (5.4),

-0.16 ^2
@ProcessEng

Ap _ 32 0.0394 Re

L ' K P8cDi

/ \ -0.16 / \
Ap 4G G 2
— = 0.127 7457
L I kD, p y [ptf]
 74 Introduction to Process Engineering and Design

0.122 9024Gl-8V<)l6Ar4'84P"1

If G in kg/s, n in kg/(m ■ s) or in N • s/m", D,- in m, p in kg/nr,

L in m, then Ap is in Pa or in N/m2,
Normally pipe diameters are expressed in mm. If D, is in mm then

y-= 0.122 9024 xlOOO4-84 GlM p'1 -p016

= 4.07 x 1013 GI'84p016Z)/4,84p~1

If Ap is in kPa or in kN/m", then

— = 4.07 x 10"° G1-84^016 D"4'84 p-1 (5.5)

L

Example 5.1
Estimate the optimum pipe diameter for a flow of dry chlorine gas of 10 000 kg/h at 6
atm a and at 20oC through carbon steel pipe using Eq. (5.1).
Solution: For carbon steel pipe, optimum pipe diameter
rfopt = 293 G0-53 p"0-37 (5.1)
G = 10 000 kg/h = 2.7778 kg/s

M
p —_ _ P~
— X ^ — _ 6x71 X^ 273
RT T psVs (273 + 20) (1x22.4136)

p= 17.71 kg/m3
<, 53 0 37
d^opt
00. = 293(2.7778) ' (17.71)~ "

= 173.855 mm
Use next heigher size of standard pipe, i.e. 200 mm (8 in) NB standard pipe.

5.2.4 Standard Pipes

Standard pipes are available from 3 mm (1/8 in) to 600 mm (24 in) size. Standard
pipes are specified with three different diameters, namely inside diameter, out-
Process Engineering Channel

side diameter and nominal diameter. For standard pipes having diameter more
than 300 mm (12 in), nominal diameters are equal to the actual outside diameter
but for smaller pipe there is no relation between nominal diameter and inside
diameter or outside diameter.
The wall thickness of standard pipe is indicated by the schedule number as per
the US standards.

psr x 1000
@ProcessEng

Schedule Number, SCH = — (5.6)

where, psj- Safe working pressure, N/mm2

(7S = Safe allowable stress, N/mm2
 Process Design of Piping, Fluid Moving Devices and Flow Meters 75

Standard pipes are available with variety of schedule numbers; 5, 10, 20, 30,
40, 60, 80, 100, 120, 140, 160. With carbon steel pipe, schedule 40 upto 150 mm
(6 in) and with stainless steel pipe, schedule 10 are used for general purposes.
Thickness of standard pipe increases with increases in schedule number. Seam-
less standard pipes do not have welding joint. Fabricated pipes are fabricated by
rolling the plates followed by joining the ends of plate by welding which are also
known as Electric Resistance Welded (ERW) pipes.
In malric system (including those specified in Indian Statndards), thickness of
a pipe is specified in mm.
Thickness of pipe, subjected to internal pressure, is determined by equation.

nr. nr..
t= — + CA = — + CA (5.7)
gE - 0.6 p gE + 0.4 p

where, t = Thickness of pipe, mm

p = Internal design pressure, N/m
Vj = Inside radius of pipe, mm
r0 = Outside radius of pipe, mm
g= Allowable stress of pipe material at design temperature, N/m2
E = Joint efficiency; for seamless standard pipe E = 1
CA - Corrosion allowance, mm

5.2.5 Pressure Drop in Fittings and Valves

In addition to pipes, piping system contains fittings and valves. These fittings
and valves offer the additional frictional loss or additional pressure drop. This
additional frictional loss of a fitting or of a valve is expressed either as an equiva-
lent straight pipe length {Le) or as a number of velocity heads {K), lost in pipe of
same size and of same material.

5.2.5.1 Equivalent Length of Pipe (LJ

Equivalent length of a valve or of a fitting is the length of straight pipe of same

Process Engineering Channel

size creating the same friction loss as the fitting or valve in consideration.
Nomographs for finding equivalent length of pipe for various fittings and valves
are given in various books (Ref. 4, 5 and 6).

4
Often, L is expressed in terms of inside diameter of pipe. Then Le = — D
A
where, D, = Inside diameter of pipe.
@ProcessEng

Values of LJDj for few valves and fittings are given in Table 5.3.
 Introduction to Process Engineering and Design

Table 5.3 Equivalent Lengths of Fittings and Valves

Le Equivalent length
Valve or fitting
Dj Inside diameter

Gate valve (fully open) 7 to 10

Gate valve (3/4 closed) 800 to 1100
Gate valve (1/2 closed) 190 to 290
Globe valve (fully open) 330 to 480
Angle valve, (fully open) 165 to 220
Plug valve, (fully open) 18
90° elbows (standard radius) 30
45° elbows (long radius) 5.8
45° elbows (short radius) 8.0
Return bend (medium radius) 39 to 56
Coupling or union Negligible
Tee, straight through 22

Another way of calculating pressure drop through the fittings and valves is the
use of factor K.
"Number of velocity heads (K) lost in pipe" for fittings or valves is defind by
equation

AF kp'P
(5.8)
v2l2gc v212gc

Kpv2 . 0
or Ap = , tn SI system, gt. = 1 (5.9)
2 gr

where, AF = Additional frictional loss, J/kg or N - m/kg

Ap = Additional pressure drop, N/m~
v = Average fluid velocity, m/s
Values of K for normally used fittings and valves are given in Table 5.4.

Table 5.4 Equivalent Velocity Heads of Fittings and Valves

Process Engineering Channel

Type of fitting or valve Equivalent number of velocity heads (K)

(applicable only for turbulent flow)

Gate valve (open) 0.17

Globle valve, bevel seat (open) 6.0
Plug valve (open) 9.0
Diaphragm valve (open) 2.3
@ProcessEng

Angle valve (open) 2.0

Check valve (swing) 2.0
Foot valve 15
Coupling 0.04
90° elbows (standard) 0.75
90° elbows (long radius) 0.45
(Contd.)
 Process Design of Piping, Fluid Moving Devices and Flow Meters 77

Table 5.4 (Could.)

45° elbows (long radius) 0.2
45° elbows standard 0.35
Tee streight through 0.4
Butterfly valve (a = 5°) 0.24

Simpson7 has given values of K for variety of other fittings, such as miter bends,
different types of reducers, different bends, etc.

Example 5.2
Carbon dioxide is to be conveyed from the top of the stripper of ammonia plant to urea
plant. Calculate the pipe size required based on following data.
Flow rate of CCb = 1000 t/day
Total length of pipe = 800 m
Available pressure at inlet of pipe = 24 kPa g
Discharge pressure of CCX from pipe required = atmospheric
No. of 90° elbows in pipe line = 8
No. of butterfly valve = 1
No. of flow nozzle = 1
Temperature of gas = 60oC
Viscosity of CCb gas = 0.016 mPa' s or cP
Solution:
Density of carbon dioxide (CO2) gas:

pM
P
r =
RT
p = 1 atm. Molar mass of CCb, M = AA

atm - m3
R = 0.0821 -, T = 273 + 60 = 333 K
(kmol • K)

1x44
p= = 1.6094 kg/m
0.0821x333

1000 xlO3
Process Engineering Channel

Mass flow rate of CO-), m = = 11.574 kg/s

24 x 3600

Let the velocity of gas through pipe, v = 20 m/s

KD2_m,P
4 '' v

11.574/1.6094
@ProcessEng

= = 0.3596 m2
20
Dj = 0.677 m
Selecting fabricated pipe having inside diameter, D, = 677 mm
 78 Introduction to Process Engineering and Design

Reynolds number

Di vp 0.677x20x1.6094
Re =
H 0.016 xlO"3

= 1361 955 > 10 000 (i.e. turbulent flow)

Pressure drop in straight steel pipe for turbulent flow

— = 4.07 x 10l0Gl'84/i0 l6
Dr4'84p"1 (5.5)
I—j
= 4.07 x 10lo(11.574)l"84(0.016 x 10-3)0 l6(677r4-84( 1.6094)-'

= 7.8046 x lO-3 kPa/m = 7.8046 Pa/m

Pressure drop in butterfly valve:

K-ipv1 0.24 x 1.6094 x202

^Pe\
2 2
= 77.25 Pa
Pressure drop in 90° elbow (standard):

K. pv2 0.75 x 1.6094 x202

^PE2 ~
2 2
= 241.41 Pa
Pressure drop in the flow nozzle is considered negligible.
Total pressure drop in pipe line
A/?, = 7.8046 x 800 + 77.25 + 8 x 241.41 = 8252 Pa = 8.25 kPa
Available pressure is 24 kPa. Hence, to decrease the fixed cost, smaller pipe can be
considered. Similar calculations for smaller pipe sizes give the following results.

Table 5.5 Comparison of Pressure Drop Calculations

Nominal Size Schedule No. ID of Pipe, mm A/?, kPa

677 mm — 677 8.25

600 mm (24 in) 20 590.55 15.558
500 mm (20 in) 20 488.95 37.525
Process Engineering Channel

Select 600 mm, SCH-20 pipe size for the given duty.

Example 5.3
Calculate the pipe size based on following data. Fluid flowing through pipe is carbon
monoxide. Discharge pressure of carbon monoxide required from the pipe is atmos-
pheric.
@ProcessEng

Available pressure at inlet of pipe = 50 kPa g

Length of pipe = 4 km
Flow rate of CO = 1500 kg/h
Temperature of gas = 50° C
No. of gate valves in pipe line = 2
No. of 45° elbows = 3
 Process Design of Piping, Fluid Moving Devices and Flow Meters 79

Nos. of 90° elbows = 6

Viscosity of CO = 0.018 mPa • s or cP
Solution:
Density of carbon monoxide (CO) gas:
Molar mass of CO, M = 28

pM
P=
RT

pM Ts 1 x 28 273
x = x
T psVs (273 + 50) (1x22.414)
= 1.0558 kg/m3
Pressure drop in straight pipe for steel material and for turbulent region:

= 4.07 x 1010 G1-84 /i016 d;AM p-{ (5.5)

i-j
For the first trial calculations let the nominal size be 12 in NB (300 mm), SCH-40 pipe
having inside D, = 304.8 mm.

—= 4.07 x 1010 ^ j (0.018 x lO"3 )a 16 x (304.8 )~4-84 x (1.0558 r"

= 1.2724 x lO"3 kPa/m = 1.2724 Pa/m

1500
4x
Am 3600
Reynolds numbers, Re = ——— = —^ ^ —
nDiii ^x 0.3048x0.018x10"

= 96 697 > 10 000, i.e. CO is flowing in turbulent region

m 1500/3600
Velocity of gas, v = = = 5.4 m/s
2 2
nx-D 1-0558 x (7r/4)(0.3048)
H 4 '■

For gate valve.

2
K.' pv
' 0.17 x 1.0558 x 5.42 ^ y t T *T/ ,/
Process Engineering Channel

= —-— = = 2.617 N/nr pter gate valve

K, pv2 0.35 x 1.0558 X5.42

Similarly for 45° elbows, A/7£2 = —-— =

= 5.388 N/m2 per 45° elbow

K: pv2 0.75 x 1.0558 x5.42

@ProcessEng

For 90° elbows, ApE3 = —-— = = 11.545 N/m" per 90° elbow

Total pressure drop in pipe line

Ap, = 1.2724 x 4000 + 2.617 x 2 + 5.388 x 3 + 11.545 x 6
Ap, = 5180.27 Pa = 5.18 kPa = 0.0511 atm
 Introduction to Process Engineering and Design

For 300 mm NB SCH-40 pipe, pressure drop in piping is very low. Hence, to reduce the
fixed capital investment, smaller pipe diameter can be considered. Similar calculations
of smaller pipe diameters gives the following results.

Table 5.6 Comparison of Pressure Drop Calculations

Nominal Size Schedule No. ID of Pipe, mm A/?,, kPa Remarks

100 mm (4 in) SCH-40 102.26 1012.38 Very high

150 mm (6 in) SCH-40 154.05 139.75 Higher
200 mm (8 in) SCH-40 202.72 37.10 Reasonable
300 mm (12 in) SCH-40 304.80 5.18 Very low

Considering fixed capital investment, operating cost and safety margin in design, 200
mm (8 in) SCH-40 pipe can be selected for the given application. For this size of pipe,
velocity of gas through pipe is equal to 12.23 m/s which is acceptable (refer Table 5.1).

Example 5.4
100 000 kg/h of water is to be transferred from canal to reservoir by gravity. Maximum
height of water level above the discharge of pipe in reservoir will be 2 m. Difference
between minimum level of water in canal and maximum level of water in reservoir is
8 m.
Length of pipe = 3000 m
Equivalent length of pipe for fittings and valves = 200 m
Maximum temperature of water = 40oC
Density of water at 40oC = 993 kg/m3
Viscosity of water at 40oC = 0.67 mPa • s or cP
Surface roughness for carbon steel, s = 0.0457 mm
Surface roughness for concrete, e= 1.2 mm
Material of pipe is carbon steel. Determine the suitable pipe size. If material of pipe is
concrete will there be any change in pipe size required?
Solution:
Maximum allowable pressure drop in pipe = 8 - 2 = 6 m WC
APmax = 6 m WC = 58.84 kPa = 0.58 atm
Let the velocity of water through pipe v = 0.5 m/s (For first trial calculation)
Process Engineering Channel

m/p (100 000)/3600

v = 0.5 m/s =
(71/4) Dp 993x(7r/4)D,2

Z), = 0.2669 m = 266.9 mm

Select 300 mm NB. SCH-40 carbon steel pipe.
ID of pipe, D, = 304.8 mm, p = 0.67 x 10"3 kg/(m • s)
@ProcessEng

4G 4 x (100 000/3600)
Reynolds number. Re = = 173 188
nDip tt x 0.3048 x 0.67 x 10 -3

M457=I.499x10-
A 304.8
 Process Design of Piping, Fluid Moving Devices and Flow Meters 81

From Fig. 5.1,/= 0.0042

32f G2
Pressure drop in pipe. Ap = xL (5.2)
K1PZc Di

32 x 0.0042 x (100 000/3600 Y x (3000 + 200)

Ap= 7 7
x 993 X 1 x 0.3048

Ap = 12 871.2 Pa = 12.871 kPa < Apmax

For the next smaller size of pipe, i.e. for 250 mm NB, SCH-40 pipe, Di = 254.5 mm,
Re = 207 417.3,

= 1.7956 x 10-4, /= 0.0041 and Ap = 30.959 kPa < Apn

D:
Use 250 mm NB SCH-40 carbon steel pipe.
If pipe material is concrete, then for the same size

— = -^- = 4.715 xlO-3 and Re = 207 417.3

Dj 254.5
From Fig. 5.1,/= 0.0077
Pressure drop Ap = 58.142 kPa s Apmax
Thus calculated pressure drop is nearly equal to the maximum allowable pressure drop.
For safer design, next higher size of concrete pipe, i.e. 300 mm (12 in) pipe, should be
used.

Example 5.5
An organic liquid is discharged at the rate of 5000 kg/h from a reactor to a storage tank
at 50oC as shown in Fig. 5.2. Reactor is under pressure at 600 kPa g. Density of the
organic liquid is 930 kg/m1 and viscosity is 0.91mPa • s or cP. Assume no flashing of the
organic liquid across the control valve.

Flow control
Orifice
valve
meter
-Hll— -CX- -Hxl—►
Process Engineering Channel

Reactor at 600 kPa g Organic Liquid

Storage Tank at
Atmospheric Pressure
@ProcessEng

Fig. 5.2 Liquid Flow System

Piping System Details:

Linear length of straight pipe = 50 m
No. of 90° elbows of standard radius = 6 (All are not shown in Fig. 5.2.)
No. of Tees = 2
 82 Introduction to Process Engineering and Design

Pressure drop in orifice meter = 40 kPa

No. of gate valves = 4
No. of globe valve = 1
No. of flow control valve = 1
Determine the pipe size. Assume it to be uniform throughout. Also find the residual
pressure drop that must be taken by the flow control valve.
Solution:
Flow rate of liquid, m = 5000 kg/h
Volumetric flow rate of liquid
m 5000/3600
qv
~~p~ 930
= 1.4934 x 10-3 m3/s
Based on Table 5.1, select velocity of liquid to be 1.8 m/s.
Inside diameter of pipe required based on selected velocity

,4X9
Df= -
" TTXV

'dx 1.4934 xlO-3

= 0.0325 m = 32.5 mm
tt xl.8

Selected 40 mm (1.5 in) NB, SCH-40 pipe having D, = 40.894 mm

Di vp 0.040 894x1.8x930
Reynolds number. Re = = = 752 27 (i.e. turbulent flow)
V 0.91 xlO-3
For the turbulent flow in commercial steel pipe

— = 4.07 x 10'° G1'84/t0"16D~4'84p-1 (5.5)

L

= 4.07xl0,n^^^l (0.91 x lO-3 )016 x(40.894r4-84 x (930)-'

= 0.413 65 kPa/m
Linear length of pipe = 50 m
Process Engineering Channel

Table 5.7 Equivalent Lengths of Fittings and Valves

Type No. Pipe ID. mm Le, m (From Table 5.3)

90° Elbows 6 40.894 6(300,) = 7.36

Tees 2 40.894 2(220,)= 1.8
Gate valves 4 40.894 4(107),)= 1.636
@ProcessEng

Total 10.796

Total pressure drop

Apr = 0.413 65 (50 + 10.796) + Pressure drop in orifice meter
= 0.413 65 (50 + 10.796) + 40 = 65.15 kPa
 Process Design of Piping, Fluid Moving Devices and Flow Meters 83

Pressure balance:
Pressure in Reactor -A/?, - A/?conlI.0| va|vc = Pressure in storage tank
(600 + 101.325) - 65.15 -Apc = 101.325
Apc = 534.85 kPa
This residual pressure drop should be offered by the control valve. Specifications of the
control valve should be prepared accordingly.

5.3 PROCESS DESIGN OF FLUID MOVING DEVICES

It includes process design of pump, fan, blower and compressor.

5.3.1 Process Design of Pump

Pump is a device used in flow system of liquid to increase the mechanical energy
of the flowing liquid. Pumps are broadly divided in to two types; (i) centrifugal
pumps and (ii) positive displacement pumps. The following terminologies are
used with pump.
(i) Capacity of pump : Flow rate (gv) of fluid created by the pump is
known as capacity of pump. In SI units, capacity
is expressed in m3/h or L/s.
(ii) Total Dynamic Head : Total dynamic head H of a pump is the difference
between total discharge head hll and total suction
head hs.
H=hd-hs (5.10)
Before installation of pump it is possible to estimate the total discharge head hd
by using following equation.
hd = hsd+hfd (5.11)
where, hsd = Static discharge head = p'± Z' (5.12)
p' = Absolute pressure over free surface of liquid in receiver
Z' = Vertical distance between free surface of liquid in receiver and
centre line of pump placed horizontally (for vertical pump Z' is
distance between free surface of liquid and eye of suction of
impeller)
hsd = p' + Z', if pump is below the level of free surface of liquid in
receiver and hsd — p' - Z', if it is placed above the free surface of
Process Engineering Channel

liquid in receiver.
hfd = Discharge friction head = frictional loss in discharge line.
During operation, total discharge head hdcar\ be determined by following equation.
hd = hgd + atm pressure + hvd (5.13)
where, hgd = Discharge gauge pressure measured by pressure gauge. If pressure
is below atmospheric, vacuum gauge reading is used for hgd in
@ProcessEng

Eq. (5.13), but with negative sign.

hvd = Velocity head at the point of guage attachment in discharge line
Before installation of pump, total suction head can be estimated by following
equation
hs = hss-hfs (5.14)
 84 Introduction to Process Engineering and Design

where, hss = Static suction head = p ±Z

p = Absolute pressure over free surface of liquid at source
Z = Vertical distance between free surface of liquid at source and center
line of horizontal pump (or suction eye impeller for vertical pump)
hss = p + Z,if pump is going to be installed below the free surface of
liquid
hss = p - Z, if pump is going to be installed above the free surface of
liquid
= Friction loss in suction line
In existing installation, total suction head hs can be determined by following
equation.
hs = atm pressure + h^s + hvs (5.15)
where, hss = suction gauge pressure,
hvs = velocity head at the point of gauge attachment.
(iii)NPSH
Net positive suction head is the excess of sum of velocity head and pressure
head in suction line over the vapour pressure head of liquid. When pump instal-
lation is designed, available net positive suction head (NPSH)A must be equal to
or greater than net positive suction head required; (NPSH)R.
(NPSH)r is normally specified by pump supplier, while based on the installa-
tion of pump, (NPSH)a should be calculated and specified by the process engi-
neer. Theoretically (NPSH)A should be greater than zero to avoid cavitation.
(NPSH)r depends on properties of liquid, the total head, pump speed, capac-
ity and impeller design. Practical curves of (NPSH)R vs capacity and speed of
pump are supplied by pump manufacturer. Figures 5.3 and 5.4 can be used as a
guideline to find the value of (NPSH)R, for centrifugal pump handling water at
temperatures below 100oC and above 100oC, respectively.

30
25
20
15
bay^
e1c
10 V.a\" ,
55J oj.
Process Engineering Channel

£
c2 7.5
X ^5,
C/)
0- 5 *\Kx
Z 550 •tyy 10 ba
4 < \0
cen 5
750 rpnTbety. V,'A3
3

2 :jy<\
@ProcessEng

1.5
«/1 O O O o o o s o «/■> O o-i O o o o o
<N ^ oc ON o rq o-i r- o •n o o-i o
— — rq rq m r^i
Capacity, m3/h

Fig. 5.3 Net Positive Suction Head for High Pressure Centrifugal Hot-Water Pumps8
(Reproduced with the Permission of Hydraulic Institute. USA)
 Process Design of Piping, Fluid Moving Devices and Flow Meters 85

X
c/o
0-
Z

^5
-o
<

100 150 200

Water Temperature, 0C
Fig. 5.4 Temperature Correction Chart for Net Positive Suction Head Requirement for Centrifugal
Hot Water Pumps8
(Reproduced with the Permission of Hydraulic Institute. USA)

When a pump installation is being designed, the available net positive suction
head (NPSH)Acan be calculated by following the equation.
(NPSH)a = hss - hfs -pv (5.16)
where, hss = Static suction head, m = p ±Z
hfs = Friction loss in suction line, m of liquid column
pv = Vapour pressure of liquid at suction temperature expressed in m
of liquid column
Process Engineering Channel

For existing installation, (NPSH)A can be determined by following equation

(NPSH)a = atm pressure + hgs - pv + hvs (5.17)
where, hgs = suction gauge pressure, m of liquid column
pv = vapour pressure of liquid at suction temperature expressed in m of
liquid column
hvs = Velocity head at the point of gauge attachment, m of liquid
column.
@ProcessEng

As a general guide (NPSH)A should be above 3 m for pump capacities upto a

flow rate of 100 mVh, and 6 m above this capacity.

5.3.2 NPSH Requirement for Liquids Saturated with Dissolved

Gases

In many situations, the liquid to be pumped is saturated with gases, which

have definite solubilities in the liquid. When a suction system for such a liquid is
 Introduction to Process Engineering and Design

to be designed for a centrifugal pump, (NPSH)A calculations differ from

Eqs. (5.16) or (5.17).
Pumping of cooling water (saturated with air), pumping of condensate from a
knock-out drum of a compressor, pumping of solution from an absorber, etc. can
be cited as examples of such situations where the liquids are saturated with gases.
Dissolved gases start desorbing when the pump is started and suction is gener-
ated at the pump eyes. Normally a pump can tolerate 2 to 3% flashed gases at the
pump eye without encountering cavitations. If the design of the suction system is
made to restrict about 2.5% flash, it is considered safe for the pump operation.
In Eq. (5.16) suction source pressure is the system pressure {p) minus the
vapour pressure (/?,,) for a normal liquid having practically no dissolved gases.
For a liquid saturated with dissolved gases, pv is replaced by pva which is called
artificial liquid vapour pressure. For evaluation of pva, following procedure is
recommended.
(a) Calculate molar mass of the gas mixture, dissolved in the liquid.
(b) Calculate mass fraction (w0) of the dissolved gas mixture.
(c) Calculate psuedo critical properties of the dissolved gas mixture, if system
pressure is high.
(d) Calculate specific volume of the dissolved gas mixture (V^) at the operat-
ing conditions.
Steps (a) to (d) can be avoided if the solubility of the gas mixture in the
liquid (such as air in water) is known from the literature.
(e) Calculate volume fraction of the dissolved gas (GYP) in a hypolheorelical
gas-liquid mixture. Considering one unit mass of the liquid in which the
gas mixture is dissolved. If GYP is less than or equal to 2.5%, Eq. (5.16)
can be safely used to calculate (NPSH)A using vapour pressure (/?,,) of the
liquid at the operating temperature. If higher than calculate volume fraction
(a) of flashed gas mixture (as pressure is lowered) over the liquid, saturated
with the dissolved gas mixture, using following equation9.

/ \2 / \
p Pv Pv
1-
[po Po J v Po /
\ / \
Process Engineering Channel

(Vca (p P
11
K [po V Po /

where, p = liquid pressure at pump eye, kPa

pv = vapour pressure of liquid at the operating temperature, kPa
Pq = system pressure, kPa
=
specific volume of the dissolved gas mixture, m3/kg [see step
@ProcessEng

Vca
(d) above]
VL = specific volume of the liquid at the operating conditions, m3/kg
Equation (5.18) assumes that the dissolved gas mixture follows ideal gas
law, Dalton's law and Henry's law.
 Process Design of Piping, Fluid Moving Devices and Flow Meters 87

(f) Calculate a for different value of p. Draw a graph of a vs p. Read corre-

sponding to a = 0.025 which is called pva. Alternately by trial and error,
calculate pva, for a = 0.025.
(g) Use Eq. (5.16) and insert pva in place of pv and calculate (NPSH)A. The
above procedure is well exemplified in example 5.10.

5.3.3 Power Required for Pumping

Power required for pumping an incompressible fluid is given by equation:

Hqvp
P= — (5.19)
3.67 x 105 x 77

where, P = Power required, kW

H = Total dynamic head, m of liquid column
p = Fluid density, kg/m3
p = Efficiency of pump
qv = Capacity, nrVhr

Example 5.6
A centrifugal pump draws benzene from an overhead tank. Operating pressure in the
tank is 700 torr a. Vertical distance between free surface of liquid in tank and centerline
of pump is 12 m. Maximum operating temperature is 50° C. Vapour pressure of benzene
at 50oC is 280 torr. Density of benzene at 50oC is 870 kg/m3. Frictional loss in suction
line of pump is 1 m of benzene column. Calculate the (NPSH)A of centrifugal pump.
Solution:
(NPSH)A = hss - hfs -pv (5.16)
hss = p + Z
p = 760 - 700 = 60 torr a
1 atm = 10.33 m water column

60 in„ Density of water 6o iqoo

p= x 10.33 x = x 10.33 x = 0.937 m
760 Density of benzene at SOX 760 870

280 1000 . „
pv = x 10.33 x = 4.37 m
v
760 870
Process Engineering Channel

(NPSH)A = p + Z- hfs - pv = 0.937 + 12 - 1 - 4.37 = 7.567 m

Example 5.7
A centrifugal pump is drawing methanol from an underground tank. Operating pressure
in the underground tank is 1 atm. Vertical distance between centre line of pump and free
surface of liquid in the tank is 3 m. Maximum operating temperature is 50° C. Vapour pressure
and density of methanol at 50° C are 400 ton- and 785 kg/m3. respectively. Friction loss
@ProcessEng

in suction line is 1 m of liquid column. Calculate the (NPSH)A of centrifugal pump.

Solution:
(NPSH)a = hss - hfs -pv = p-Z-hfs -pv (5.16)

n = 10.33 x-^^ = 13.16 m LC

785
 Introduction to Process Engineering and Design

400 ]A „ 1000
p = x 10.33 x = 6.926 m LC
v
760 785
(NPSH)a = 13.16 - 3 - 1 - 6.926 = 2.234 m LC
Selection of the pump is critical. As a general guideline (NPSH)A should be greater than
3 m for a centrifugal pump.

Example 5.8
Installation of pump is to be decided for the following application. Pump will handle hot
water at a temperature of 176.70C and a suction pressure of 1.034 MPa g. Capacity of
pump will be 10 m3/h. It is planned to use a centrifugal pump with single suction for this
applications. Speed of its impeller will be 2900 rpm.
Find the minimum distance that must be kept between free surface of liquid at source
and centre line of horizontal centrifugal pump.
Solution:
(NPSH)a > (NPSH)r
From Figs 5.3 and 5.4, data for cetrifugal pump having a speed of 3550 rpm are given.
Assume these data to be applicable for 2900 rpm (a safer design). For 3550 rpm, 10 m3/h,
176.70C and p < 35 bar:
(NPSH)r = 3.048 + 3.6576 m (additional)
(NPSH)r = 6.7 m
(NPSH)a > 6.7 m
p±Z-hts-pv>6J m
p = 1.034 MPa g = 1.034 x 106 Pa g
1 atm = 101.325 kPa
p = (1.034 x 1()6+ 101.325 x I03) Pa
p= 1.135 325 x 106 Pa
Vapour pressure of hot water at 176.70C = 0.928 MPa
pv = 0.928 x 106 Pa
Density of water at 176.70C, p = 890 kg/m3

, 0.207 325 xlO6

p - p., = 0.207 325 x 106 =
pxg

0.207 325 xl 06
= 23.746 m of WC
890x9.81
Process Engineering Channel

Select the pipe size and piping system such that hfs < 1 m.
-Z- I + 23.746 > 6.7 m
(if pump is installed above the free surface of liquid at source)
or Z< 16,046 m
Pump can be installed maximum up to an elevation 16.046 m above the free surface
of liquid at source to avoid cavitation. Pump can be installed at any distance, if it is to be
@ProcessEng

installed below the free surface of liquid at source.

Example 5.9
In the previous example, if hot water is saturated at 176.70C temperature at source, what
will be the minimum height that must be kept between free surface of liquid at source
and centre line of selected pump? Type, speed and capacity of pump are same as that for
previous example.
 Process Design of Piping, Fluid Moving Devices and Flow Meters 89

Solution:
For the single suction centrifugal pump having speed 2900 rpm and capacity 10 rnVh
(NPSH)r = 6.7 m
(NPSH)a > (NPSH)r or (NPSH)A > 6.7 m
Here hot water is saturated at 176.7° C at source.
P=Pv
In this case pump must be installed below the free surface of liquid at source.
(NPSH)a = p + Z - hfs - pv = Z - hfs > 6.7 m
Let the velocity of water in suction line = I m/s

qv = vx (73/4)7)2 = 10 m3/h = 2.7778 x lO"3 m3/s

4 X qv 4 x 2.7778 xlO-3
D: = — =0.059 47 m
y TT X V ]J nxl
From the table of standard pipe select 62.5 mm NB SCH-40 steel pipe having
Dj = 62.71 mm

DjVp
Re=
P
p of water at 176.70C = 890 kg/m3
Velocity based on D, = 62.71 mm, v = 0.9 m/s
Viscosity of water at 176.70C and at saturation pressure, 9.08 atm a must be determined.
Effect of pressure on viscosity of liquid is insignificant, up to about 50 atm.
For reduced temperature T,. < 0.75, relation between viscosity of liquid and temperature
is given by equation

In u. = , rin/f
r+c
where C = 17.71 - 0.19 Tb, Tb in K
For water, C= 17.71 - 0.19 (100 + 273) =-53.16
From Appendix 14 of Ref. 10:
^i49oc = 0.185 cP, Pws.vc - 0.242 cP or mPa • s
B
In (0.185) = A + -, In (0.242) = A +
[(149 + 273) -53.16] [(115.6 + 273) -53.16]
A+ 0.0027 112 B = -1.6874, A + 0.002 981 /? =-1.4188
Process Engineering Channel

A = -4.3865, B = 995.55
995 55
In pw = 4.3865
[(176.7+ 273)-53.16]
pw = 0.1532 cP or mPa ■ s at 176.70C
fiw = 0.1493 mPa • s at 180oC from JSME Steam Tables
@ProcessEng

0.062 71x0.9x890
Re = = 327 876.7 (i.e. turbulent)
0.1532 xlO"3

For turbulent flow through commercial steel pipe

— = 4.07 x 1010 m1"84 /t016 Di 4 84

p"1 (5.5)
1/
 90 Introduction to Process Engineering and Design

qv = 10 m3//? = 2.7778 x K)"3 m3/s

3
m = mass flow rate = qvxp = 2.7778 x 10 x 890 = 2.4722 kg/s

A
" = 4.07 x I010 x (2.4722)1-84 x (0.1532 x 10"3)016 x (62.71)-4-84 x (890)
L

An
— =0.1186 kPa/m
L
For 6.7 m elevation,
let L = actual length of pipe = 7 m
Assuming three 90° elbows and one globe valve in the suction line.

Table 5.8 Equivalent Lengths of Fitting and Valve

Valve or Fitting No. Le

90° elbows (standard) 3 3 (30 D) = 5.64 m
Globe valve (open) 1 350 D =21.95 m

L = 1 + 5.64 + 21.95 = 34.59 m

4.102 x 103
Ap = 4.102 kPa = m Liquid Column (i.e. WC at 176.70C)
pxg

4.102 xlO3
h = Ap = = 0.47 m of WC
' 890x9.81
Z> (6.7 +0.47) morZ> 7.17 m
Minimum elevation required between free surface of water at source and centre line of
pump = 7.17 m

Example 5.10
Carbon dioxide gas (> 99.5% pure) from ammonia plant is washed with cooling water in
a packed column before compression in urea plant at 1.01 atm a and 40oC. Cooling
water form bottom of the column is pumped back to cooling tower. Solubility of carbon
dioxide in water is 0.0973 kg/100 kg water at 1 atm and 40oC. Find the volume fraction
of carbon dioxide over cooling water. Also calculate artificial liquid vapour pressure.
Solution:
Process Engineering Channel

Molar mass of carbon dioxide, M = 44.0095

From JSME Stream Tables, vapour pressure of water at 4()0C,
pv = 0.073 75 bar
= 0.0728 atm
Mass fraction of carbon dioxide in the liquid

0.0973x1.01
@ProcessEng

VVo =
(100 + 0.0973)

= 9.8177 x 10-4

9.8177 x 10-4 xO.08206x313.15

=
44.0095xl.01
= 5.676 x 10-4 m3/kg H20
 Process Design of Piping, Fluid Moving Devices and Flow Meters 91

From JSME Steam Tables

VL = 1.0078 m,3//kg H20 at 40oC

5.676 x 10"4 x 100

GVP =
->-4 •
(1.0078 +5.676 x 10 )

= 0.0563%
Thus, volume per cent of carbon dioxide is only 0.0563% (< 2.5%) over cooling water
and there is no danger of pump cavitation.
p0 = 1.01 atm

P 0.0728 Vr 0.0728)
1.01 1.01 J I 1.01 j
a= 1/ +1 (5.18)
-4
5.676x10 p
1.0078 1.01 1.01

By trial and error,

For p = 0.145 atm, a = 0.0247
Hence, pva = 0.145 atm
Thus, if vapour pressure of water (0.0728 atm) is used instead of pva (i.e. 0.145 atm),
(NPSH)a would have been erroneous by 0.75 m H2O.
Above calculations indicate that at higher temperature and lower suction pressure,
pva could have significantly affected (NPSH)A.

Example 5.1 I
Benzene at 37.80C is pumped through the system at a rate of 9.09 nr/h with the help of
a centrifugal pump. The reservoir is at atmospheric pressure. Pressure at the end of
discharge line is 345 kPa g. The discharge head is 3.05 m and the pump suction head is
1.22 m above the level of liquid in reservoir. The friction loss in suction line is 3.45 kPa
and that in the discharge line is 37.9 kPa. The mechanical efficiency of the pump (77) is
0.6. The density of benzene is 865 kg/m3 and its vapour pressure at 37.80C is 26.2 kPa.
Calculate (a) (NPSH)A and (b) power required by centrifugal pump.
Solution:
(a) (NPSH)a = hss-hfs-pv = p-Z-hfs - pv
Process Engineering Channel

101.325 xlO3
p = 1 atm = = 11.94 mLC
865x9.81
Z = 1.22 m

3.45 x 103
hfs = 3.45 kPa = = 0.4066 m LC
865x9.81
pv = 26.2 kPa = 3.088 m LC
@ProcessEng

(NPSH)a = 11.94 - 1.22 - 0.4066 - 3.088 = 7.2254 m of LC

(b) Power required by centrifugal pump

H
%P
P= (5.19)
3.67 x10s xtj

p' = Pressure at discharge = 345 + 101.325

 Introduction to Process Engineering and Design

446.325 xl 03
p' = 446.325 kPa = = 52.6 m LC
865x9.81
Z' = 3.05 - 1.22 = 1.83 m
hsd = 52.6 + 1.83 = 54.43 mLC

37.9 xlO3
hfd = 37.9 kPa = = 4.47 m LC
1
865x9.81

hd = 58.9 m LC
h=h„-hf=p-Z-hfK = 11.94 - 1.22 - 0.4066 = 10.31 m
H = 58.9 - 10.31 = 48.59 m

48.59x9.09x865
p= = 1.735 kW
3.67 xl05x 0.6

Example 5.12
It is proposed to pump 10 000 kg/h of saturated toluene at 1140C and 1.1 atm a from the
reboiler of a distillation tower to a second distillation unit without cooling. If the friction
loss in the line between the reboiler and pump is 7 kPa and the density of toluene is 866
kg/m3, how much liquid level in the reboiler be maintained to give a net positive
suction head of 2.5 m? Calculate the power required to drive the pump if the pump is to
elevate the toluene to 10 m to a second unit at atmospheric pressure. Assume friction
loss in the discharge line to be 35 kPa. Pump efficiency is 62 %.
Solution:
In this case the pump is installed below the liquid level.
(NPSH)a =p + Z-hfs-pv = 2.5 m
Liquid in reboiler is saturated liquid at reboiler conditions. Therefore, p = pv
Z-hfS = 2.5 m

7x103
n 7000
hf. = 7 kPa = =
' pxg 866x9.81

= 0.824 m LC
Z = 2.5 + 0.824 = 3.324 m
Process Engineering Channel

Pump must be installed at a level 3.324 m below the free surface of liquid in reboiler.
Power required to drive the pump

Hqvp
P= 7 (5.19)
3.67 xlO5 x p
@ProcessEng

p = 1 atm = 101.325 kPa = m LC

pxg

101325
= 11.927 mLC
866x9.81
 Process Design of Piping, Fluid Moving Devices and Flow Meters 93

Z' = 10 m
hsd = 10+ 11.927 = 21.927 m
35 000
hcj = 35 kPa = = 4.12 m LC
866x9.81
hd = 2\.927 + 4.12 = 26.047 m
Total suction head hs = hss - hfs = p + Z- hfs (5.14)

111.4575 xlO3
p= 1.1 atm = = 13.12 mLC
866x9.81
h..= 13.12 + 3.324-0.824= 15.62 mLC
H = hdd-
-Khs == 047 - 15.62 = 10.427 m LC

10000
<?v = = 11.5473 m3/h
866

10.427x11.5473x866
P= : = 0.4582 kW
3.67xlO5 x0.62

Example 5.13
Hexane at 37.80C is pumped through the system at a rate of 9.09 m Vh. The tank is at
atmospheric pressure. Pressure at the end of discharge line is 345 kPa g. The discharge
head is 3.05 m and the suction lift is 1.22 m above the level of liquid in the tank. The
friction loss in suction line is 3.45 kPa and that in the discharge line is 37.9 kPa. The
mechanical efficiency of the pump is 0.6. The density of hexane is 659 kg/m3 and its
vapour pressure at 37.80C is 33.71 kPa.
Calculate (a) (NPSH)A and (b) power required by centrifugal pump.
Solution:
(a) (NPSH)a = hss - hfs -pv=p-Z- hfs - pv

101.325 xlO3
p = 1 atm = = 15.67 m LC
659x9.81
Z = 1.22 m

3.45 xlO3
Process Engineering Channel

hf, = 3.45 kPa = = 0.534 m LC

7
659x9.81
pv = 33.71 kPa = 5.214 mLC
(NPSH)a = 15.67 - 1.22 - 0.534 - 5.214 = 8.702 m of LC
(b) Power required by centrifugal pump

H
%P
P = (5 19)
@ProcessEng

—. ^ -
3.67 x 10 x tj

p' = pressure at discharge = 345 + 101.325 kPa = 446.325 kPa a

446.325 x 103
p' = 446.325 kPa = = 69.04 m LC
659x9.81
 Introduction to Process Engineering and Design

Z' = 3.05- 1.22 = 1.83 m

hsd = 69.04 + 1.83 = 70.87 m LC

37.9 xlO3
hfd = 37.9 kPa = = 5.86 m LC
7
659x9.81

hd = 70.87 + 5.86 = 76.73 m LC

hs = hss - hfs = p-Z-hfs = 15.67 - 1.22 - 0.534 = 13.916 m
H = 16.73- 13.916 = 62.814 m

62.814x9.09x659
P= = 1.71 kW
3.67 x 105 x 0.6

Example 5.14
A centrifugal pump is drawing water from an overhead tank, exposed to atmosphere.
Vertical distance between free surface of liquid in the tank and center line of pump is 10 m.
Capacity of centrifugal pump is 10 000 kg/h. Maximum operating temperature is 50oC.
Vapour pressure of water at 50oC is 92.51 torr. Total length of suction pipe 10.5 m,
having two 90° elbows. Determine the size of suction pipe and (NPSH)A of centrifugal
pump. Material of pipe is carbon steel. Density of water = 1000 kg/m3, Viscosity of
water = 0.558 mPa ■ s (or cP).
Solution:
In Table 5.1, velocity of water in suction line v is recommended in the range of 0.3 to
1.5 m/s
Let velocity of water in suction line, v = 1 m/s

n
D2^qv ^1Qx(i/36Q0)
4 v 1
D, = 0.0595 m
Select 62.5 mm NB SCH-40 pipe, D, = 62.7 mm

qv _ (10000/3600)(l/1000) _ 2.778xlO"3

^ x (0.0627)2 ^ x (0.()627)2
Process Engineering Channel

Actual velocity, v = 0.9 m/s through the selected pipe.

D: vp 0.0627x0.9x1000
Re= =
X 0.558 xlO-3

= 101 129
Surface roughness of carbon steel, e = 0.0457 mm
@ProcessEng

£ 0 0457
—= = 0.000 729
Di 62.7
 Process Design of Piping, Fluid Moving Devices and Flow Meters 95

From Fig. 5.1, /= 0.005

Ap _ 32/G2 _ 32x0.005 x (10 000/3600)2 ^^

L n2 p gc Df ^2 x 1000 x 1 x 0.06275

= 129 Pa/m
For 90° Elbows, additional pressure drop

Kpv2
APf_=^— (5.9)
2gc

0.75x1000 x(0.9)2
Ap,- = = 303.75 Pa per elbow

Total pressure drop in suction line

Apr= 129 x 10.5 + 303.75x2

1.962 xlO3
Ap. = 1962 Pa = 1.962 kPa = = 0.2 m WC
1000x9.81
For 62.5 mm NB SCH-40 pipe,
(NPSH)a = hss - hfs - pv = p + Z- hfs -pv (5.16)

101.325 xlO3
p = 1 atm = = 10.33 m WC
1000x9.81

=
92 51 = 0.1217 atm = 0.1217 x 10.33 s 1.26 m WC
w
760
(NPSH)a = 10.33 +10- 0.2 - 1.26 = 18.87 m

Example 5.15
A centrifugal pump is used to transfer hot water at 110oC from a deaerator to boiler as
shown in Fig. 5.5. Hot water is saturated liquid in the deaerator at 110oC. Capacity of
pump is 16.5 m3/h and its efficiency is 60%. Speed of the impeller is 2900 rpm. Pipe
line to the boiler contains one control valve and five 90° bends. Its straight length is
25 m.
Calculate:
Process Engineering Channel

(a) Recommended size of suction line

(b) Minimum vertical distance Z required between lowest liquid level in the deaerator
and center line of pump and
(c) Recommended size of pipe line to boiler.
Solution:
(NPSH)a > (NPSH)r
For the single suction centrifugal pump having speed 2900 rpm and capacity 16.5 m3/h
@ProcessEng

rpm x ^ = constant

2900 x yj 16.5 = 3550 x

 Introduction to Process Engineering and Design

M 1-
— H

u ro Q u

+-
u
'J-!

u.

^^

ou
n
UOIJBTnD.1103^
umuxiuijAj
O a
<x.

n- o-
o
o
o Qh
o
=5
-J CQ a:
o
H
Q
-J

a.
-

-j
Process Engineering Channel

# # // d

Sfi
@ProcessEng

in y:
m
 Process Design of Piping, Fluid Moving Devices and Flow Meters 97

x = 11 m3/h
Operating pressure, p = 0.147 MPa g (From JSME Steam Tables corresponding to the
110oC saturation temperature.)
p = 0.147 MPa g = 248.325 kPa = 2.48 bar < 35 bar
From Figs 5.3 and 5.4, (NPSH)R = 3.048 + 0.4572 = 3.5052 m, say 3.5 m
(NPSH)r = 3.5 m
(NPSH)a = p + Z-hfs-pv>3.5m
In the deaerator, water is saturated, hence p=pv
Z - hp > 3.5 m
Let hfs= 1 m (assumed) Z> 4.5 m
Zmin = 4.5 m. Suggested Z = 5 m Ans. (b)
Size of suction line:
Let velocity of hot water in suction line = 1 m/s (Table 5.1)

16 5/3600
— Df = —= - = 4.5833 x KT3 nr
4 ' v 1
Dj = 0.0764 m
Select 75 mm NB, SCH-40 MS pipe
Z), = 77.92 mm

DjVp
Reynolds number Re = —^—

Velocity of water based on 77.92 mm diameter, v = 0.961 m/s

Viscocity water at 110oC, p. = 0.256 mPa • s (or cP), p at 110oC = 950.12 kg/m3

0.077 92x0.961x950.12
Re= = 277 914.3
0.256 x 10"3

Surface roughness of steel pipe = 0.045 72 mm (Table 5.2)

e 0.045 72
= 0.000587
D: 77.92

From Fig. 5.1,/= 0.0045, G = 16.5 x —x 950.12 = 4.3547 kg/s

6 S
3600
Process Engineering Channel

A/? 32/ G2
(5.2)
1 2
n p8cD-

32 x 0.0045 x 4.35472

;r2 x950.12x 1x0.077925

= 101.38 Pa/m
@ProcessEng

For 90° elbows, additional pressure drop

Kp\2
aPe = -
2gc
 Introduction to Process Engineering and Design

0.75x950.12x0.9612
A/7£ = = 329.05 Pa per elbow

Total pressure drop in suction line,

Ap, = 101.38 x 5 + 1 x 329.05 = 835.95 Pa

835.95
= 0.09 m WC
950.12x9.81

Corrected value of Zmin = 3.59 m, say 3.6 m

The recommended size of suction line is 75 mm NB, SCH-40 pipe and minimum verti-
cal distance Zmjn required between lowest liquid level in deaerator and center line of
pump is 3.6 m. Ans. (a) and (b)
Size of discharge line to boiler:
Let the velocity of water in discharge line, v = 2 m/s

K qv
= = 16.5/3600
4 v 2

D,- = 0.054 m
Select 50 mm (2 in) NB, SCH-40 MS pipe for which D, = 52.5 mm
Velocity of water based on 52.5 mm inside diameter v = 2.12 m/s

DjVp 0.0525x2.12x950.12
Re = =
fi 0.256 xl 0"3

= 413 079.5
Surface roughness of steel pipe e= 0.045 72 mm

p 0.045 72
—= = 8.7 x 10
D 52.5
From Fig. 5.1, /= 0.0047
G = 4.3547 kg/s
For the turbulent flow through steel pipe,

2
Ap 32/ G2 32 x 0.0047 x 4.3547

K- x 950.12 x 1 x (0.0525)5
Process Engineering Channel

L K- pgc Df

= 762.6 Pa/m

Table 5.9 Equivalent Velocity Heads of Fittings and Valves

Fittings/valves No. (n) K

Gate valve 1 0.17

@ProcessEng

Controll valve 1 6
90° Bends 5 0.75
Check valve 1 2
 Process Design of Piping, Fluid Moving Devices and Flow Meters 99

Total pressure drop in discharge line

Ap . pv2
Ap, = — x straight length + (X A", n-,) -
L 2gc

(0.17 + 6 + 0.75 x 5 + 2) x 950.12 x 2.122

= 762.6 x 25 +
2x1

= 19 065 + 25 450.5 = 44 515.5 Pa = 44.515 kPa

This value of pressure drop is within permissible limit.
Hence size of discharge line to boiler is recommended to be 50 mm NB, SCH-40.

Example 5.16
Crude dichlorobenzene is pumped from a storage tank to a distillation column. The tank
is blanketed with nitrogen and the pressure above the liquid surface is held constant at
0.1 bar g. The minimum depth of liquid in the tank is 1 m.
The distillation column operates at a pressure of 500 torr a. The feed point to the
column is 12 m above the base of the tank. The tank and column are connected by a
50 mm internal diameter commercial steel pipe, 200 m long. The pipe, running from the
tank to the column, contains the following valves and fittings; 20 No. of standard radius
90° elbows, two gate valves (fully open), an orifice plate and a flow control valve.
If the maximum flow rate required is 20 000 kg/h, calculate the power required by
pump. Pump efficiency is 70%. Pressure drops across the control valve is 0.5 bar. Den-
sity of the dichlorobenzene is 1300 kg/m3 and viscosity is 1.4 m Pa • s (or cP).
Flow meter/Valve/Elbows Equivalent number of velocity heads, K
(i) Standard radius 90° Elbows 0.75
(ii) Gate valve (Fully open) 0.17
(iii) Orifice meter 10
Solution:
Power required by pump is calculated by following equation

Hqv p
P= (5.19)
3.67 xlO5 X T]

20 000
= 15.3846 m3//i
Process Engineering Channel

qv =
1300
p = 0.7
H
= Kt - K = (p' + Z' + v -(p + Z- hfs)
p' = Operating pressure in distillation column
p' = 500 torr a = 66 661.184 Pa
To convert p' in m of liquid column,
@ProcessEng

66 661.184 66661.184
p' = = = 5.227 m LC
pxg 1300x9.81

2' = 12 m
p = 0.1 bar g
 100 Introduction to Process Engineering and Design

or /? = 10 000 + 101 325 = 111 325 N/m2 a

111 325
= 8.7293 mLC
1300x9.81

Z= 1 m
hfs = Friction loss in suction line s 0 m LC
hfd = Total friction loss in discharge line in m of liquid column

^ - ^
"fa
pxg

where. A/? = Total pressure drop in discharge line

Velocity of dichlorobenzene in discharge line
qv 15.3846 x (1/3600)
v= = = 2.1765 m/s
2
-D? — x(0.05)
4 ' 4 V ^
D: vp 0.05x2.1765x1300
Re = — = = 101 052 > 4000
R 1.4 x 10~3
Flow is turbulent.
For the turbulent flow of fluid through commercial steel pipe

— = 4.07 xl0l()Gl-84p,) l6
D"4 84p-1
L
1.84
|0J
| 20 000 "i| w in-3\O.I6 w/irn\-4.84 ^/.orvnx-l
10
= 4.07 Xio (1.4xlO-J)U10 xisor^ x(1300)
I 3600 )
= 1.535 73 kPa/m

Ap 3
Ap, = — x L + Ap of control valve
L )
+ Ap across 90° elbows, gate valves and orifice meter

pv
= 1.535 73x 103 x 200 + 0.5 x 105 + (20 x 0.75 + 2 x 0.17+1x10)x
2
Process Engineering Channel

25.34 x 1300 X2.17652

= 307146 + 50 000 +
2
= 435 171.63 Pa = 435.172 kPa

435171.63
hM = = 34.123 m LC
1
1300x9.81
@ProcessEng

H = (5.227 + 12 + 34.123) - (8.7293 + 1 +0)

= 41.62 mLC

41.62x15.3846x1300
P
= 7
3.67 x 10 x 0.7

= 3.24 kW
 Process Design of Piping, Fluid Moving Devices and Flow Meters '0'

5.4 EVALUATION OF CENTRIFUGAL PUMP PERFORMANCE

WHEN HANDLING VISCOUS LIQUIDS

When centrifugal pumps, designed and tested for handling water are used for
viscous liquids, significant increase in power consumption and decrease in head
and capacity occur.
Figures 5.6 and 5.7 provide means of determining the performance of a con-
ventional centrifugal pump handling a viscous liquid when its performance on

IV.
0.8
0.7
ill.
0.5
ii.l \ r;
0.3
ii :
0.1
Viscosity - C enlislok es (c!

V-
Process Engineering Channel

.
@ProcessEng

Viscosity SSU %

10 11 12 13 14 15 18 20
Capacity, m'/h

Fig. 5.6 Viscosity Correction Chart8

(Reproduced with the Permission of the Hydraulic Institute. USA)
 Introduction to Process Engineering and Design

100

0.6 x Qn
X 0.8 x Qn
1.0 x 0n
1.2 x Qn

c
O 100
c -r.
C3 SK
U- o
= ~ P
o c 80
z: a
3 >>
C T.
C a
U C^-
u1 60 O

40

20
c>❖ -i> Viscosity - Centistokes
J' -o v tI?? 1
\%0

.b« bO

A® \1

60

■-E

-O ,
S
Process Engineering Channel

n&
SO 40
10 \1-
^-AS
» h
Viscosity - SSU^

2.5 3 3.5 4 4.5 5 6 7 S 9 10 II 13 IS 17 19 22 25 30 35 40 50 60 70 80 90 110 130 170190220

@ProcessEng

Capacity, £/v. x 10 m3/h

Fig. 5.7 Performance Correction Chart8

(Reproduced with the Permission of the Hydraulic Institute. USA)

water is known. The same can also be used as an aid in selecting a pump for a
given application.
 Process Design of Piping, Fluid Moving Devices and Flow Meters *03 |

Limitations on use of viscous liquid performance correction chart (Figs 5.6

and 5.7):
(i) Extrapolation is not recommended.
(ii) Use only for pumps of conventional hydraulic design in the normal operating
range with open or closed impellers. Do not use for mixed flow or axial
flow pumps
(iii) Use only for Newtonian liquids. Do not use for gels or slurries or other
non-Newtonian liquids.

Example 5.17
Performance of a centrifugal pump on water is known. It can deliver 9.5 m3/h of water at
50 m total head of water with 80% efficiency. By using Figs 5.6 and 5.7 predict the
performance of this pump if it is used to deliver lubricating oil with 43 x 10 3 nr/s (or 43
cSt) viscosity at 40oC. Determine the percentage change in Head, Capacity and Power
required by the pump. Density of lubricating oil at 40oC is 869 kg/m3 at the operating
temperature.
Solution:
Power required by centrifugal pump for delivering 9.5 m3/h of water at 50 m total head
with 80% efficiency

Hqvp
P= (5.19)
3.67 x 105 x 77

(Density of water at 40oC. p = 992.215 kg/m3 from Table 3.28 of Ref. 2)

50x9.5x992.215
P= = 1.605 25 kW
3.67 xlO5 x 0.8

Enter the graph (Fig. 5.6, viscosity correction chart) with 9.5 m3/h capacity, go up to 50 m
head, over to 43 cSt viscosity, and then up to the correction factors.
Cq = 0-9
C„=l
CF = 0.71
Capacity of centrifugal pump when it handles the lubricating oil

Goii = CqQw = 0-9 x 9.5 = 8.55 m3/h

Head developed by pump
Process Engineering Channel

Hoi] = CHxHw= 1 x 50 = 50 m
Efficiency of pump £oi| = CF x Ew = 0.71 x 0.8 = 0.568
Note that there is a significant drop (29%) in the efficiency.
Power required by pump when it handles the lubricating oil,

. Hon x Qol] x poil 50 x 8.55 x 869

P' = ————= = 1.7821 kW
3.67 x 105 x £oil 3.67 x 105 x 0.568
@ProcessEng

(9.5-8.55)
% decrease in capacity of pump = — x 100 = 10%
 Introduction to Process Engineering and Design

decrease in head developed of pump = 0% (i.e. no change)

(1.7821-1.605 25)
increase in power required by pump = x 100= 11.02%
1.605 25

Example 5.18
Figure 5.8 shows the performance curve of a centrifugal pump operated on water. If the
same pump is used for handling oil with a specific gravity of 0.9 and a viscosity of 1000
SSU (220 cSt) at the pumping temperature, develop the performance curve of the same
pump for oil.

30
0.90 SP - 25
1000-SSU - 20
Water - 15
- 0
- 5

'000 ssn
P 30
t'r 00
90
-a SO

X 20 Efficiency 70 >-■
1000 SSU 60
©-^
50
40 W
30
20

50 100 150 201) 250

Capacity m-Vh

Fig. 5.8 Sample Performance Chart

Solution:
Process Engineering Channel

On the performance curve for water, locate the best efficiency point. In this example
from Fig. 5.8 (from the efficiency vs capacity curve for water), it is 170 m3/h. For water
with 170 m3/h capacity, efficiency of pump is maximum (86%). Tabulate capacity, head
and efficiency for 0.6 x 170,0.8 x 170 and 1.2 x 170 m3/h flow rates. By using Fig. 5.8,
for 170 m3/h, 31 m of head is developed by the pump when it handles the water (from
head v,y capacity curve for water).
Enter the graph (Fig. 5.7, viscosity correction chart) with 170 mVh capacity, go upto
@ProcessEng

31m head, over to 1000 SSU (220 cSt) viscosity and then up to correction factors.
CE = 0.645
Cq = 0.95
Q = 0.895 (for 1.2 xQN)
Cw = 0.92 (for 1 x Qn)
 Process Design of Piping, Fluid Moving Devices and Flow Meters '05

CH = 0.94 (for 0.8 x QN)

CH = 0.96 (for 0.6 x QN)
Sample calculations for 0.6 x <2^ capacity:
Qm, = 170 m3/h
0.6 x Qnw = 102 m Vh = Qw
Hw = 34.62 m (from head vs. capacity curve for water in Fig. 5.8)
Ew = 0.76 (from efficiency vs. capacity curve for water in Fig. 5.8)
Viscosity of oil, /J = 220 cSt
CQ = 0.95 Qoi| = CQ ■ Qw = 0.95 x 102 = 96.9 m3/h
CH = 0.96 Hoi[ = CH ■ Hw = 0.96 x 34.62 = 33.235 m
CE = 0.645 ?70il = CE ■ ilw = 0-645 x 0.76 = 0.4902
Here again, note the drop (24%) in efficiency.
Power required by pump when it handles the oil

"oil X Qo\\ X Poil 33.235 X 96.9 x 900

P=— —— = = 16.11 kW
3.67 x 105 770i| 3.67 x 105 x 0.4902

Calculation for obtaining the performance curve for oil is given in Table 5.10. Same data
are presented in Fig. 5.8.

Table 5.10 Revised Performance of Centrifugal Pump for Handling Oil

Capacity 0.6 x Qnw 0-8 x Qnw 1.0 x Qnw 1.2 x Qnw

Qw m3/h 102 136 170 204

Hw m 34.62 33.21 21 27.3
Hw 0.76 0.84 0.86 0.85
C
Q 0.95 0.95 0.95 0.95
C
H 0.96 0.94 0.92 0.895
C
E 0.645 0.645 0.645 0.645
2oii = x Qw 96.9 129.2 161.5 193.8
=:
"oil C,/X Hw 33.325 31.217 28.52 24.434
foil:::: £vrx CF 0.4902 0.5418 0.5547 0.5483
P kW 16.11 18.26 20.363 21.18
Process Engineering Channel

5.5 POWER REQUIRED IN FAN, BLOWER AND IN

ADIABATIC COMPRESSOR

Fans, blowers and compressors are used to increase the mechanical energy of
gases. Discharge pressure of a fan is less than 3.45 kPa g (350 mm WC). If
discharge pressure required is higher than 3.45 kPa g then a blower is used. Maxi-
mum discharge pressure of blower is 1 atm g. If the discharge pressure required
@ProcessEng

is more than 2 atm a then a compressor is used. Discharge pressure of compres-

sor ranges from 2 atm a to thousands of atmospheres.

5.5.1 Power Required by Fan

Fans are of two types, (i) centrifugal fans and (ii) axial flow fans. Efficiency of a
 Introduction to Process Engineering and Design

fan ranges from 40 to 70%, depending on its specific speed. Power input to a fan
is given by equation.
Pn=2.72x 10-5 VvPd (5.20)
where, P0 = Power required by fan, kW
qv = Capacity of fan, m Vh
p(l = Discharge pressure of fan, cm WC

5.5.2 Power Required in Blower and in Adiabatic

Compressor

Blowers are always operated in an adiabatic manner. Many compressors are also
operated in adiabatic manner (Example: air compressors uplo 10 bar g). In
adiabatic compressor, jacketed cooling is not provided. While in other types;
polytropic and isothermal compressors, jacketed cooling is provided around the
compressor suction. In isothermal compressor inlet temperature of gas is equal to
outlet temperature of gas. If both temperatures are not same even after providing
the jacket cooling, it is called polytropic compressor.
For adiabatic compression

Pi 'vT*-' Pi k-I
ill (5.21)
P\ u T2 v. P\ 7i

k = cPicx
k = ratio of specific heat at constant pressure to specific heat at constant
volume
P2t P\ = outlet/inlet pressure of gas, kPa
Vj, Kj = outlet/inlet volume of gas , m3
T^, T) = outlet/inlet temperatures of gas , K
Power required in single stage blowers or in single stage adiabatic compressor.

k-\
P7_
P, = 2.78 x 10-4 qv\ P\ -1 (5.22)
k-\ P\ )

where, P{) = Power required, kW

Process Engineering Channel

Px = Absolute inlet pressure, kPa

qvX = Volumetric flow rate of gas based on inlet condition, m3/h
Discharge temperature of gas from the blower or single stage adiabatic compressor,
k -i
P2_
r. =71 (5.23)
P\
@ProcessEng

Value of k ranges from 1.39 to 1.41 for air and perfect diatomic gases. For k =
1.395, value of bracketted expression in Eq. (5.22) is known as X factor

k-i
/ \ k-l
P2_ k
X = -1 =r —1 (5.24)
P\
 Process Design of Piping, Fluid Moving Devices and Flow Meters '07

where, k = 1.395 for air or a diatomic gas

r = Compression ratio
Power required for blower and adiabatic compressor
P0 = 9.81 x 10^?vl px X (5.25)
Other gases are having value of k in the range of 1 to 1.4. Power required by
blower or adiabatic compressor, for the gases having value of k other than
k= 1.395, is given by following equation.

G
P0 = 6.37 x 10~4 qv\P\ (5.26)
d
where, d = 2.292 {(k- 1) / k)

Values of and d can be obtained from Fig. (5.9) for the different values of

k and for different values of r.

1.0
XG=r^k 1^/^-1 (for gases)
X= r0;283 - I (for air)
0.9 r = ratio of comnression /

0.8 ,^c

^2^
0.7
-

=A
yy/ f
I
II
Jo

-o 0.6
c
CO r= \(y
t+H
o
c/i
0 ///
0.5 //
3
/
1
0.4 / / / // u -
v T1)-
///;
Process Engineering Channel

/
0.3

'

0.2

w
0.1 i
@ProcessEng

/
1.0 1.05 1.1 1.15 1.2 1.25 1.3 1.35 1.4
Ratio of Specific Heats , k

Fig. 5.9 (XG/X) vs k and d vs k2

(Reproduced with the Permission of McGraw-Hill Education, USA)
 Introduction to Process Engineering and Design

For a multistage compressor with N stages of compression in which

(a) adiabatic compression takes place in each stage,
(b) near equal work done in each stage (i.e. equal compression ratio in each
stage, r) and
(c) intercooling is provided between each two stages of compression to same
inlet gas temperature (Tj),
Power requirement can be calculated by the following equation.

6.37 x 10 A^vl /?,

P = a/X^TT-i) (5.27)
d
For the multistage compressor, discharge temperature from the last stage can be
predicted by the following equation.

T, = TA" Xn+l (5.28)

where, N = number of stages

Example 5.19
Find out the power required for a turbo blower for the following duty.
Fluid = Atmospheric air
Capacity = 1000 NnvVh
Discharge pressure = 2 atm a
Also find the discharge temperature of air.
Solution:
Power required for turbo blower
A--I
P2_
Po = 2.78 x 10~4 -r^—qvi A -1 (5.22)
k -1 P\
For air, k = 1.395
qvI = Volumetric flow rate based on inlet condition in m3/h

Pitfvi 1x1000
(273 + 25)
1000x1
= x (273+ 50) = 1083.9 m3//?
Process Engineering Channel

298
1.395
R. = 2.78 x 10-4 x 1083.9 x 101.325 x (2(1-395"l/l-395) - 1)
(1.395-1)
P., = 23.38 kW
Discharge temperature of Air

k-\
P2_
@ProcessEng

t2=tx (5.23)
P\

0.395
T2 =323(2)D-395> =393.04 K
Discharge temperature of air, t2 = 120oC
 Process Design of Piping, Fluid Moving Devices and Flow Meters ' 09

Example 5.20
A three stage reciprocating compressor is used to compress 306 SnrVh of methane from
0.95 atm a to 61.3 atm a. The inlet temperature is 26.7° C.
Specific heat ratio of methane, k= 1.31
Calculate (a) Power required for compression, if mechanical efficiency is 80 percent
and
(b) Discharge temperature of gas after 1st stage
Solution:
For a multistage compressor total power required is minimum if each stage consume the
same power or same compression ratio in each stage.
For same compression ratio in each stage.
1/3
61.3
Compression ratio in each stage r = = 4.01
0.95
Power required for each stage

k—I
-4
2.78x10
Pn = 7vi (5.22)
k-l pi
k= 1.31, n = 0.8
qvi = Volumetric flow rate based on inlet condition nrVh

Psqvs 1x306
P, P 273

. = 306 x (273 + 26.7)

273 0.95

1-4
2.78 x 10" 0.31
1.31
P= x 353.6 x 0.95 x 101.325 (4.01) '■3I - 1
0.8 1.31-1
= 19.45 kW
If power loss in allied piping and intercoolers is neglected, then total power required for
three stages,
P{)' = 3 x 19.45 = 58.35 kW
Process Engineering Channel

(b) Discharge temperature after lsl stage

k-\
Pi_
To = P
(Pi
T2 = (273 + 26.7)(4.01)<0'3i/i'3I)
P2 = 416.3 K, t2 = 143.30C
@ProcessEng

or
for k = 1.31 and r = 4.01, from Fig. 5.9
d = 0.54, (XG/X) = 0.8

0.395 '0.395'
X = r i -395 _ i = 4.01V 1.395 ; _ , = 0.48, 8
XG = 0.8x0.4818 = 0.3854
 110 Introduction to Process Engineering and Design

Power required for each stage

x
_4 4i.i Pi G
Pn = 6.37 xl (T4 (5.26)
n d

6.37 x IG-4 x 353.6 x96.2587 x 0 3854 = 19.34 kW

=
0.8 0.54
Total power required P0' = 3 x 19.34 = 58.03 kW
(Neglecting pressure loss in the intercoolers and allied piping)

5.6 FLOW METERS

A variety of flow meters are in use in chemical process industry. One category is
the traditional differential pressure (DP) type volumetric flow meters. In many
applications the volumetric flow rate is of direct interest to the user. Because of
its accuracy, simplicity and relatively lower cost, these flow meters are popular in
the chemical industry. By multiplying the flow rate with the actual density, mass
flow rate can be obtained. Pitot tube, orifice meter, venturi meter and flow nozzles
fall under this category. Among these, orifice meter is by far the most popular in
the industry. Figure 5.10 shows these meters schematically.
Less commonly used flow meter is vortex meter which works on Von Karman
effect. Flowing fluid separates on two sides of shedder bar face. Vortices form
behind the face and cause alternating differential pressures (DP) around the back
of the shedder.

Vena Contracta Taps

D and ^ D (Radius) Taps

Flange Taps

Comer Taps
Process Engineering Channel

iWWWWWWWWWWWWWl.ra
1"- 25.4 mm
D-
iD
t
I D
Direction of flow Distance to the
|
mean location of
Vena Contracta
@ProcessEng

Orifice plate —^
[Fig. (c)]
WWWWWWWWWWWWWWWWWWWSS \\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\

Fig. 5.10(a) Various Tap Locations for Orifice Meter

 Process Design of Piping, Fluid Moving Devices and Flow Meters '''

0.9

k
0.8 v

0.7

0.6 Sr-
N
^ 0.5 S
\
0.4 V
Vs
0.3 \

0.2

0.1
0.3 0.4 0.5 0.6 0.7 0.8
Pipe Diameters from Inlet Face of Orifice Plate
Extracted from the ASME Flow Meter Compulation Handbook, 1961
(b)

=1
1 n
\

D and f DJjpdiusu -Kb) 1

r i 1

Orifice Meter with Vena Contracta Formation

Process Engineering Channel

(c)
Fig. 5.10 Orifice Meter

The frequency of the alternating vortex development is linearly proportional

to the volumetric flow rate. Although vortex meters are as reliable and as accurate
as other DP instruments, they can be used for only clean liquids and are
@ProcessEng

recommended for turbulent flows.

Another popular category is of variable area flow meters which are also known
as rolameters. Figure 5.11 shows two different types of rotameters. While DP
type instruments can be installed in horizontal position, rotameters are installed
in vertical postion. Bypass rotameters are installed in horizontal position which
is a combination of an orifice and a rotameter. Bypass rotameters are installed on
 Introduction to Process Engineering and Design

Flow
□ 1
Upper
float stop

-mi
Out
45(1 Capacity
400 scale

Metering
float

250
Precision-bore
nn interchangeable
tapered Pyrex
50
metering tube
inn

Removable CS===g3
lower float
stop
1_U In
Standard Rotameter Magnetic Rotameter
(a) (b)
Fig. 5.1 I Rotameters

larger size pipelines and occupy quite less space. Near linear scale of the meter is
an advantage over logarithmic scale for the DP meters. However, rotameters with
glass tubes are relatively less accurate and are mainly used for low pressure
applications.
Disadvantage of low pressure applications due to glass tubes has led to the
development of magnetic rotameters in which a magnetic float is used in a metal-
Process Engineering Channel

lic tapered tube and its accurate position is monitored outside the tube. Float's
movement is calibrated on a dial type indicator. Both DP type and magnetic ro-
tameter can be connected to a microprocessor based control unit for totalizing
and/or controlling purpose.
Positive displacement type flow meters incorporate a pair of gears or a turbine
which rotate on their axes and the revolutions are measured. Since volume
displaced per revolution is nearly constant, volumetric flow is calculated by mul-
@ProcessEng

tiplying two parameters. Traditional water meters are of gear type. Turbine flow
meters are available for number of liquids such as ammonia, chlorine, etc. which
flow under relatively high pressure. These instruments are sufficiently accurate
and are used for custody transfer.
Weirs are popularly used for volumetric flow measurements in open canals
and alike situations. Figure 5.12 shows different types of weirs in use.
 Process Design of Piping, Fluid Moving Devices and Flow Meters '' 3

L Water L Water L Water

it':-
(a) Rectangular type (b) V-notch type (d
(d) Trapezoidal type

Fig. 5.12 Flow Measurement with Weirs

Another category relates to ultrasonic flow meters. Its underlying principle is

measurement of the effect a flowing fluid has on an ultrasound signal either trans-
mitted through or reflected from the fluid. These instruments are largely clamp-
on designs and offer simplicity of installation. These meters suffer from a reputa-
tion for unreliability and poor long-term stability, compared with DP type meters.
However, newer designs are being developed for high pressure and temperature
fluids, including gases. Designs are available when a single instrument can be
clamped on a range (though limited) of pipes and volumetric flows can be checked
periodically. This type of meter is quite handy to a process engineer in checking
plant performance from time to time.
Electromagnetic flow meters (also known as magmeters) work on Faraday's
law of conductance which states that when a conductive fluid flows through a
magnetic field, generated perpendicular to the flow, the voltage induced in the
fluid is linearly proportional to the volumetric flow rate. Thus, this type of instru-
ment operates only with electrically conductive liquid. Non-invasive nature of
ultrasonic flow meter is also the feature of magmeter. Both permit unobstructed
flow through the measuring element. Both are clamp on meters whose transduc-
ers are strapped to the pipeline. Unlike ultrasonic meters, magmeters have a
reputation of accuracy.
True mass flow meter based on Coriolis principle was introduced in 1977 by
Mirco Motion, Inc., USA, a division of Emerson Process Management. The
Coriolis principle, discovered by Gustave Coriolis in 1935 states that fluid flowing
through a tube, vibrating at its natural frequency, generates a force that slightly
distorts the tube. This extremely small distortion, picked up by sensors, is directly
Process Engineering Channel

proportional to the mass flow rate (Newton's second law of motion) and is inde-
pendent of any other property of the fluid; say pressure, temperature, density or
viscosity. Figure 5.13 schematically represents the mass flow meter.
In a single mass flow meter, four parameters of the fluid can be measured at a
time; mass flow, volume flow temperature, and density. This instrument offers
high accuracy and can be used for any fluid; clean or dirty, transparent or opaque,
@ProcessEng

conductive or non-conductive. Originally developed instrument required extra

space for installation but recently developed meter has a straight tube configura-
tion. Among different types of flow meters, Coriolis device is the costliest.
In the forthcoming sections, process designs of orifice meter and rotameter
are discussed. Reader is advised to refer standard handbooks on instrumentation/
flow meters for design of other flow meters.
 Introduction to Process Engineering and Design

Drive Coil

Tube
RTD for Oscillation
Temperature

Electromagnetic Velocity
Detector
5.13 Coriolis Mass Flow Meter (Courtesy: Micro Motion, Inc., USA)

^Iwwwwwws

Flow

^■SXWNV-

Flow Nozzle with Differential Gauge.

(a)

Inlet
Throat

\V2
Process Engineering Channel

D I
Pi I P2
@ProcessEng

Venturi Meter
(b)
Fig. 5.14
 Process Design of Piping, Fluid Moving Devices and Flow Meters '' 5

5.7 PROCESS DESIGN OF ORIFICE METER

Orifice meter is a widely used flow meter in chemical industry, compared to

venturi meter and rotameter. Advantages of orifice meter are:
(i) Fixed cost is less
(ii) Easy to fabricate and install
(iii) Occupies less space as compared to the venturi meter
(iv) Provides more flexibility. Orifice plate can be easily replaced.
Disadvantages:
(i) Power consumption and hence operating cost of orifice meter is higher than
the same of venturi meter and of rotameter.
In orifice meter, as shown in Fig. 5.10, a square edged or sharp edged orifice
plate is mounted between two flanges at the flanged joint. When fluid flows
through the orifice it forms free flowing jet. This free flowing jet first contracts
and then expands. Minimum flow area achieved by free flowing jet is known as
Vena Contracta.
Mass flow rate through orifice is given by following equation.

(5.29)

where m = Mass flow rate of fluid, kg/s

A0 = Area of orifice = (7r/4) , m2

P\, P2= Pressure at upstream and downstream static pressure taps, respecti-
vely, Pa
p = Density of fluid, kg/m3

^ Diameter of orifice

Inside diameter of pipe

Y = expansion factor
= 1 for liquids
= 1 - [((1 - r)/£)(0.41 + 0.35 p4) ] for gases (5.30)

Pi
Process Engineering Channel

where, r = —, ratio of downstream to upstream pressure

C
p
k = , specific heat ratio
Cv
C0 = Coefficient of orifice = f{Re0, p. Location of taps)
@ProcessEng

where, Re0 = Reynold's number for the fluid flowing through orifice

d0u0p 4m /c oi\
Re0= = —— (5.31)
P Kd0p
where, u0 = Velocity of fluid through orifice, m/s
p = Viscosity of fluid, kg/(m • s)
 Introduction to Process Engineering and Design

Equation of orifice meter (Eq. 5.29) is empirical in nature and it requires ex-
perimental support.
In addition to Re0 and C0 also depends on the location of pressure taps.
Location of pressure taps on upstream side and down stream side are also stand-
ardised as discussed in Fig. 5.10 (a).
There are total five standard locations of pressure taps.
(i) Corner taps: Static holes made in upstream and downstream flange. They
are very close to the orifice plate. With corner taps, it is possible to drill
both static holes in the orifice plate itself. Then entire orifice meter can be
easily inserted in any flanged joint without drilling the holes in pipe or
flanges.
(ii) Flange taps: Static holes made at a distance 25.4 mm on upstream side
and 25.4 mm on downstream side.
(iii) Radius taps: Static holes located at a distance one pipe diameter on up-
stream side and 1/2 pipe diameter on downstream side. Radius taps are the
best from practical stand point of view as it gives reasonably good pressure
difference, compared to other taps except vena contracta taps. Higher
pressure difference means more accurate measurement of flow rate.
(iv) Vena contracta taps: Upstream static hole is 1/2 to 2 limes pipe diameter
from the plate. Downstream tap is located at the position of minimum
pressure. Vena contracta taps give the maximum pressure difference for a
given How rate. But it is not suitable, if orifice size is changed from time to
time.
(v) Pipe taps: Static holes are located at 2.5 times pipe diameter upstream side
and 8 limes pipe diameter on down stream side. This means fluid is flowing
normally on both sides without being affected by turbulence, created by the
orifice plate.
For Re0 > 30 000,
C0 = Between 0.595 to 0.62 for vena contracta taps
C0 = Between 0.595 to 0.8 for radius taps
C0 = 0.62 for corner taps
Relation between discharge coefficient C0 , {3 and ReD is given by Stolz
equation (ISO: 5167).
Process Engineering Channel

C0 = 0.5959 + 0.0312 /321 - 0.184 /38 + 0.0029 /3 25 {\06/ReDf75 + 0.09 L,

/34 (1 - /I4)'1-0.0337 L2 p2 (5.32)
where ReD = Reynolds number based on internal diameter of pipe D
/ i \ / x
I /h_
^ = ' L, -
v do j
@ProcessEng

where, d0 = diameter of orifice

P=d0/D
/j = Distance of the upstream tapping from the upstream face of
orifice plate, mm
/7 = Distance of the downstream tapping from the downstream face
of the orifice plate, mm
 Process Design of Piping, Fluid Moving Devices and Flow Meters ' '7

Example 5.21
Design an orifice meter based on the following data.
Name of fluid = water
Flow rate = 100 000 kg/h
Inside diameter of pipe = 154 mm (6 in, SCH-40 pipe)
Operating temperature = 320C
Density of water at 320C = 995.026 kg/m3
Viscosity of water at 320C = 0.765 mPa ■ s or cP
Manometer fluid = Mercury
Density of Mercury at 320C = 13 516.47 kg/m3
Solution:
Inside diameter of pipe D = 154 mm
Let = 0.5, dJD = 0.5
diameter of orifice, d0 = 77 mm
ReD = Reynolds number based on inside diameter of pipe

4,'n 4 x (100 000/3600)

Ren =
kDh tt x 0.154 x 0.765 x 10"3

= 300 210.2
Use square edged circular orifice plate with radius taps.
Radius taps are best from practical stand point. In radius taps downstream tap is located
approximately at the mean location of vena contracta (1/2 times pipe diameter) and also
upstream tap is sufficiently far so that it is not affected by distortion of flow in the
vicinity of orifice.
Based on Stolz's equation Eq. (5.32),

/ - \0.75
21 8 25 106
C() =0.5959+ 0.0312)3 - - 0.184/3 +0.0029 )3 '
ReD

+ 0.09 L, /r (1 - /3 )"' - 0.0337 L, pi (5.32)

h h
Z = = 1 = = 1
-' 7T
D ^- T-
d0
C0 = 0.5959 + 7.2776 x K)"3 - 7.1875 x lO-4 + 1.264 x K)"3 + 6 x K)"3
- 4.2125 x l(r3
Process Engineering Channel

= 0.6055
Mass flow rate of water

28cAPP
m = C,. FA, (5.29)
1 i-P
Y = expansion factor for liquid = 1
@ProcessEng

100000 n , 2x I x An x 995.026
= 0.6055 x 1 x —(0.077) x
3600 4 ]l i -0.5

Ap = 45 722.597 Pa = 45.722 kPa = 4.661 m WC

 Introduction to Process Engineering and Design

A
/' = — ( Pm - P f )

9.81
45 722.597 = /?,„ x (13 516.47-995.026)
1
Rm = Manometer reading = 0.3722 m Hg
= 372.2 mm Hg
In actual industrial practice, DP transmitter is used. Select the transmitter with 5500 mm
WC range so that the normal reading is at about 85% of the range.
Similarly, one can find different values of Rm for the different variation in flow rate or
in other words calibration of orifice meter can be carried out.

Example 5.22
Design an orifice meter based on the following data.
Name of fluid = Chlorine gas
Flow rate = 1500 NnrVh
Operating Pressure =1.2 atm a
Operating temperature = 30oC
Viscosity of Chlorine gas at 30oC = 0.0145 mPa • s or cP
Inside diameter of pipe = 154 mm (6 in. SCH-40)
Specific heat ratio for Cf gas = 1.355
Solution:
Let [5=0.5

d.
= 0.5 or d„ = 77 mm
D

4m
ReD =
kDH
Density of Cf gas at normal condition

1x71 273
P= x = 2.902 kg/m
(273 + 25) 1x22.414

m = 1500 x 2.902 = 4353 kg/h

4x(4353/3600)
Process Engineering Channel

Re,, = \-3
^ x 0.154 x 0.0145 x 10"

= 689 457.6
If corner taps are made then /, = /2 = 0
Coefficient of orifice meter can be determined by Stolz's equation.
,0.75
21 J2.5 lO'
C(, =0.5959 + 0.0312 /3 - -0.184 p* +0.0029 P (5.32)
@ProcessEng

Re D
+ 0.09L, p4(\-p4)-' - 0.033712p3
= 0.5959 + 7.2776 x lO"3 - 7.1875 x 10^ + 6.7755 x lO"4
= 0.6031
 Process Design of Piping, Fluid Moving Devices and Flow Meters ' '9

Expansion factor
y = 1 - [((1 - r)/k){0Al + 0.35f?)]
= 1 -[((1 -r)/1.355)x 0.4319]
For the first trial calculation let r = 0.8, Y = 0.9362
Mass flow rate of chlorine gas

n ,2 l2gcAPP
m = C0Y-d0 (5.29)
1-/34

Density of chlorine gas at operating condition:

1.2x71 273
P= x = 3.425 kg/nr
(273 + 30) 1x22.414

4353 K -> 2xlx A/?x3.425

= 0.6031 x 0.9362 x -(0.077)2 x
3600 4
i l-O.S4

A/?= 28 946.4 Pa
= 28.946 kPa
p, = 1.2 atm,/jj =/?! - Ap = 1.2 x 101.325 - 28.946
p2 = 92.644 kPa

Pi 92 644
r=—= = 0.762, y = 0.9241
p] 121.59

Apoc or Y2 = a
^r \ P2 Y2

Ap^ = 28.946 x I()'9362 1 = 29.7 kPa

V 0.9241 J

(121.59-29.7)
r= = 0.7557 s 0.762 (close enough to the previous value of r)
121.59
Ap2 = 29.7 kPa = 3.028 m WC (final)
Similary, for the different variation in the flow rate A/i can be determined. In this case
also, a DP transmitter having 3500 mm WC range can be selected. Normal reading will
Process Engineering Channel

be at about 87% of the range.

5.8 PROCESS DESIGN OF ROTAMETER

Rotameter is used for the flow measurement of liquids and gases. It is a variable
flow area meter in which pressure drop is nearly constant and the area through
which the fluid flows varies with the flow rate. It consists of tapered tube with the
@ProcessEng

smallest diameter at the bottom. The lube contains a freely moving float which
rests on a stop at the base of the tube. When the fluid is flowing the float rises
until its weight is balanced by the upthrusl of the fluid, its position then indicates
the rate of flow. Float is not floating but it is completely submerged in the fluid
and its density is greater than the density of fluid. The tube is marked in divisions
 Introduction to Process Engineering and Design

and the reading of the meter is obtained from the scale reading at the reading
edge of the float which is taken at the largest cross section of the float. It is
always mounted in the perfect vertical position. Rotameters are designed to
# o o
meausure the flow rate of fluid in certain range like 5 nr/h to 50 nr/h,
10 mVh to 100 nrVh. 3 Lpm to 30 Lpm, etc.
For a linearly tapered tube with a diameter at the bottom about the float diam-
eter, flow is almost a linear function of the height or position of float. As a tube
material glass is the first choice. For high temperatures or pressures or for other
conditions where glass is impracticable, metal tubes are used. In this case since,
in metal tube, the float is invisible, means must be provided for either indicating
or transmitting the meter reading.
Mass flow rate through rotameter is given by equation

2
_r , gy/(pf-p)p

where, qm = Mass flow rate, kg/s

CD = Discharge co-efficient depends on the shape of the float and the
Reynolds number though annulus. It can be obtained from litera-
ture such as Fig. 2.22 of Ref: 11. For the float having the shape
same as shown in Fig. 5.15, value of CD is almost constant for the
value of Re above 500 and it is 0.775.
/42 = Cross sectional area of annulus between float and tube, m2
=
At A | — Ay
A | = Cross sectional area of tube at the float position, m2
2
Ay — Maximum cross sectional area of the float in a horizontal plane, m

\ 40 mm
Process Engineering Channel

E
£
r- 5 mm
A V
fN 5 mm
5 mm
15 mm
@ProcessEng

25 mm

25 mm ^^

Fig. 5.15 Typical Details of Float and Tube

 Process Design of Piping, Fluid Moving Devices and Flow Meters '21

g = Acceleration of gravity = 9.81 m/s~ at mean sea level

Vf = Volume of float, m3
Pj - Density of float, kg/m3
p = Density of fluid, kg/m3

Example 5.23
Determine the minimum and maximum flow rates of water at 40oC, which can be meas-
ured by rotameter of the given dimensions. Dimensions of tube and float of rotameter
are given in Fig. 5.15.
Viscosity of water of 40oC = 0.7 cP or mPa ■ s
Density of water at 40oC = 992.2 kg/m3
Float material = Stainless steel
Density of stainless steel = 8000 kg/m3
Float is made from stainless steel plate of 2 mm thickness. Calibrate the rotameter or
find the different values of flow rates for the different float positions.
Solution:
Volume of float:

'25 + 15^' -9
2 x —(] 5)2 x 5 + — x5 x 10
4 4

6 3
V
Vf = 3.338 x 10" m
Mass of float:

15 + 25
W,= 2x—(15) +7r(15)(10) + —(25 -15 ) + 7r x5
4 4 2

xlO"6 x 0.002x8000
= 0.023 25 kg

0.023 25
Density of float = = 6965 kg/m3
V,/ -6
3.338x10
Maximum flow rate at top:
Mass flow rate through Rotameter is given by equation
Process Engineering Channel

2gVf(Pf-p)p
Qm - Cn ^2 (5.33)
2'
1-
U z

For the 1st trial calculation, let discharge coefficient, CD = 0.75.

@ProcessEng

A/ = Cross sectional area of tube

TC
= ^ (40)2 = j256.6 mm" = 1256.6 x lO"6 m2

Af = Maximum cross sectional area of the float in a horizontal plane, m2

= - (25)2 = 490.87 mm2 = 490.87 x lO"6 nr

4
 '22 Introduction to Process Engineering and Design

A2 = Cross sectional area of annulus between float and tube, m2

A2 = A, -Af= 765.767 x lO"6 nr, — =0.6094

^1

2 x 9.8lx 3.338 x 10"6 x 992.2

x (6965-992.2)
qm = 0.75 x 0.765 767 x 101-3
490.87 x lO-6[ 1 - 0.60942 ]

= 0.6441 kg/s
= 2318.78 kg/h = 2.337 nrVh (taking p = 0.9922 kg/L for water)
Mass velocity through annulus:

G = ^L = 2
r =841.12 kg/(m -s)
3
^2 0.765 767 xlO"
Equivalent diameter:

4 x Cross Sectional area

d„ =
Wetted Parameter

4 x 765.767 xl0"6
= = 0.015 m
^"(40+ 25)x 10

d G 0.015x841.12
Re = = — = 18 024
R 0.7 xlO"3
From Fig. 6.22 of Ref. 11
CD= 0.775

= 0J75_ x 0 644 = 0 6655 k ,

Hm 5
0.75
= 2395.7 kg/h = 2.414 nrVh (corrected)
First mark for indicating flow rate is at 27 mm diameter of tube.

Ai= j (27)2 = 572.55 mm2 = 572.55 x lO-6 m2

Process Engineering Channel

A2 = Ai -A/= 81.685 x 10-6m2

— =0.142 67
A
Let CD = 0.775 (for lsl trial)
@ProcessEng

2 x 9.81 x 3.338 x 10"6 x 992.2

x (6965-992.2)
qin = 0.775 x 81.685 x lO-6
490.87 xl0"6[ 1-0.142 672]

= 0.056 873 kg/s = 204.7 kg/h = 0.2063 m3/h

 Process Design of Piping, Fluid Moving Devices and Flow Meters

0.056 873
G= \-6 = 696.25 kg/(m ■ s)
81.685x10

4x81.685 xlO-6
d = = 0.002 m
^ k{21 + 25) x 10-3

de G 0.002 x 696.25
Re = = 1989.3
-3
0.7x10

For Re = 1989.3, CD = 0.775 (from Fig. 6.22 of Ref. 11). Flence, no change in qm or qy
Based on similar calculations. Table 5.11 is prepared.

Table 5.1 I Flow Rate Calculation for Rotameter

Tapered tube A. A2/Ai qv ■ m3/h

Diameter, mm mm2 mm2

25 490.87 — — 0
27 572.55 81.685 0.142 67 0.2063
30 706.85 215.98 0.3056 0.5672
32 804.25 313.38 0.3897 0.85
34 907.92 417.05 0.4593 1.174
36 1017.876 527 0.5178 1.54
38 1134.11 643.24 0.5672 1.9528
40 1256.6 765.73 0.6094 2.4148

Let angle made by tapered tube with vertical plane is 2 degrees.

Let h = Float position in mm from the bottom most point (i.e. from the point where
diameter of tube is 25 mm)
For qv = 2.4146 nrVh, inside diameter of tapered tube = 40 mm
Value of h at 40 mm diameter
(40 - 25)12
h= = 214.77 mm
tan 2
Similarly float position, h can be determined for the different flow rates.

Table 5.12 Float Position Calculations for Rotameter

Process Engineering Channel

Diameter of tapered tube, mm qv, m3/h h, float position from bottom, mm

25 0 0
27 0.2063 28.64
30 0.5672 71.59
32 0.85 100.23
@ProcessEng

34 1.174 128.86
36 1.54 157.5
38 1.9528 186.135
40 2.4148 214.77

Draw the graph of h vs qv.

Refer Fig. 5.16.
 Introduction to Process Engineering and Design

240

220

200

180
s
£
| 160 x
oP'V
co
CQ 140 ,0°
S
g
u. 120
1——
'Si
P.O 100
_ora
E 80

60 / /
//
40

20

0
0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8
Flow Rate, qv, m^/h

Fig. 5.16 Calibration of Rotameter

Example 5.24
In Example 5.23 a rotameter is calibrated to measure the flow rate of water at 40oC. If
the same rotameter is used for measuring the flow rates of following fluids then what is
the change in calibration?
(a) Monoethylene glycol (MEG) brine containing 60% MEG by mass12
Operating temperature: -250C
Operating pressure: 3 bar g
Density: 1098 kg/m3
Viscosity: 40 mPa • s (or cP)
Process Engineering Channel

(b) Ethyl alcohol

Operating temperature: 350C
Pressure: 3 bar g
Density: 781 kg/m3
Viscosity: 0.9 mPa • s (or cP)
Solution:
@ProcessEng

At the top most position of the float,

h = 214.77 mm, diameter of tapered tube = 40 mm,

A.
A, = 1256.6 mm-, A2 = 765.73 mnr, — = 0.6094
At
 Process Design of Piping, Fluid Moving Devices and Flow Meters '25

For this position of float, flow rate of MEG:

2gVf ipf -p)p

Qm - Co ^2 (5.33)
2'
f A-, ^
i-
rf IA /

For the 1st trial calculations, let CV, = 0.775

2 x 9.81 x 3.338 x 10"6 x 1098 x (6965 -1098)

=0.775 x 765.73 x 10
490.87 x lO-6!! -0.6094"]

= 0.6939 kg/s

0 6939
or = - x 3600 = 2.275 m3/h
1098

0.6939
Mass velocity, G = = 906.194 kg/(m ■ s)
^2 765.73 xl0"6

deG 0.015x906.194
Re = = 339.82
40x10i-3

Value of CD = 0.77 (Fig. 6.22 of Ref.: 11)

0.77
<lm = x 0.6939 = 0.6894 kg/s
0.775
or qv = 2.26 nvVh
For the same position of float, flow rate of ethyl alcohol:
Let CD = 0.775 (for Is' trial calculations)

2x9.81 x 3.338 x 10-6 x781

x (6965-781)
qm = 0.775 x 765.73 x K)"6,
490.87 xl(r6ri-0.60942

= 0.6 kg/s
Process Engineering Channel

<7 = M X 3600 = 2.11 m3/h

v
781

In 0.6
Mass velocity, G = = 783.57 kg/(nr • s)
^2 765.73 xlO"6

deG 0.015x783.57
Re = — = ;— = 13 059.5
@ProcessEng

0.9x10 -3

CD = 0.775 (from Fig. 6.22 of Ref.: 11)

No change in the values of qm and qv.
At diameter of tapered tube = 27 mm.
Float position, h = 28.64 mm,
A, = 572.55 mm2, A2 = 81.685 mm2, A2/A, = 0.142 67
 '26 Introduction to Process Engineering and Design

Flow rate of MEG; For the Is1 trial, let CD = 0.77

2 x 9.81 x 3.338 x H)"6 x 1098(6965 - 1098)

-6
= 0.77 x81.685 x lO
\ 490.87 x 10-6[1-0.142672]
qm = 0.059 kg/s

= ( 0059 | x 3600 = () 193 44 m3/h

V 1098 )

U-059
C = —= = 722.287 kg/(m2 • s)
^2 81.685 x 10

d G 0.002x722.287
Re = = =36.114
P 40 x 10
CD = 0.7 (from Fig. 6.22, Ref. 11)

qm = x 0.059 = 0.0536 kg/s

0.77
qv = 0.1757 m3/h
For the same position of float, flow rate of ethyl alcohol:
Let CD = 0.775 (for 1st trial calculation)

6 ( 2 x 9.81 x 3.338 x lO-6 x 781 x (6965 - 781)

q = 0.775 x 81.685 x 10 ,
490.87 xl0-6(l-0.142 672)
qm = 0.051 34 kg/s
qv = 0.2367 m3/h
qm 0.05134 ,
G = —= — = 628.5 kg/(m- ■ s)
^2 81.685 xl O-6
de G 0.002 x 628.5
Re = = — = 1396.67
0.9 x 10
CD = 0.775 (From Fig. 6.22 of Ref.: 11)
Hence qm and qv remain unchanged.
By similar calculations following table is prepared.
Process Engineering Channel

Table 5.13 Flow Rates of Different Fluids for the Same Position of Float

Float position Diameter of tapered qv nrVh

h, mm tube D. mm Water MEG Solution Ethyl alcohol

0 25 0 0 0
28.64 27 0.2063 0.1757 0.2367
71.59 30 0.5672 0.5274 0.65
@ProcessEng

100.23 32 0.85 0.8 0.976

128.86 34 1.174 1.106 1.348
157.5 36 1.54 1.45 1.766
186.135 38 1.9528 1.84 2.24
214.77 40 2.4148 2.26 2.77

Following Table is made from the graph (Fig. 5.16).

 Process Design of Piping, Fluid Moving Devices and Flow Meters '27

Table 5.14 Calibration for Rotameter

v, mVh Float Position, h mm

Water MEG Solution Ethyl Alcohol
0.1 14.31 15.94 11.828
0.2 27.8 31.02 23.66
0.4 52.67 55.8 45.224
0.6 75.06 79.22 66.28
0.8 95.21 100.00 84.77
1.0 113.81 118.94 102.08
1.2 131.0 137.37 117.47
1.4 146.93 155.47 132.73
1.6 161.89 170.05 147.63
1.8 175.96 183.46 161.88
2.0 189.19 196.67 172.9
2.2 201.81 209.83 183.93
2.4 213.91 194.78

Comments: It can be seen from Table 5.13 that rotameter calibration is essentially
immune from the viscosity effect (say upto about 100 mPa. s or cP). However, calibration
is significantly affected by the density of the fluid which changes drag force.
In actual practice, rotameters are tested for actual water capacities on a test bench to
confirm the calibration.

5.9 TWO PHASE FLOW

In many applications, two-phase flow is experienced in industry. If pipe sizing is

not done properly, it can result in serious problems. A few such problems are
illustrated as follows:
(a) When a saturated liquid under pressure is flashed through a control valve,
two-phase flow will be realised in the downstream piping. Pressure drop in
the two-phase flow could be much higher (several fold in some cases) in
the pipe. This will result in much higher back pressure on the control valve,
restricting its capacity. Apart from excessive pressure drop, there could be
erosion in the pipeline.
Process Engineering Channel

(b) When vapour and liquid flow in upward direction and the line is sized for
low pressure drop, it may cause slug flow; i.e. slugs of liquid flow in vapour.
This can result in pressure pulsation and severe vibration. This phenomenon
is commonly observed and is known as water hammer in steam lines,
particularly during cold start-up when steam condenses during travel and
water slugs flow with steam. Water hammers can break open the flanges or
damage the supports. Adequate draining facility is provided on long steam
@ProcessEng

pipelines to avoid such water hammers.

(c) If cooling water is flowing downward at temperature in excess of 40oC
from a height of 10.5 m or more to an atmospheric pond, vibrations could
result due to vapour formation at the top and two phase formation in
downflow pipe. A provision of appropriate size orifice at the base of the
pipe could solve the problem.
 Introduction to Process Engineering and Design

A process engineer should visualize such a problem and design the piping
suitably so that both the phases flow smoothly without creating any problem.
Estimation of pressure drop in an isothermal two-phase system can be done
with empirical relations, developed by Martinelli's and Dukler's correlations.
Simpson7 has dealt at a length on both the correlations and original article by
Simpson may be referred for the details.
A common problem of two-phase flow is experienced in steam condensate
lines. When steam is used for heating in a heat exchanger, its condensate is
discharged through a steam trap. While the heat exchanger operates under pressure,
the trap discharges condensate to low pressure. In most cases, the condensate
line opens into an atmospheric storage tank while in a few instances, condensate
is conveyed to a deaerator, operating under positive pressure. In both cases, flashing
of condensate takes place which calls for larger size pipe. If not designed properly,
water hammer could be anticipated and also the back pressure on the trap could
be much higher than anticipated. Steam traps are sized and rated for a specific
pressure drop and condensate flow discharge rate. If the pressure drop is less
than design, trap's capacity will be reduced and condensate accumulation is
expected in the heat exchanger, thereby heat transfer will be affected.
Empirical correlations could be used for calculating pressure drop in steam
condensate pipes. However, pipe sizing could be done with the help of Fig. 5. 17
which is based on approximate pressure drop of 0.1 kPa/m (or 1 mbar/m) length
of pipe. This represents only friction loss. To this head loss and equipment pressure
(such as that of deaerator) are to be added to arrive at a back pressure of the trap.

Example 5.25
Saturated steam at 10 bar g is used in a heat exchanger at the rate of 2000 kg/h. Conden-
sate is discharged through a trap and taken to a deaerator, located at 10 m above the heat
exchanger. Pipe length, including equivalent length of fittings, is calculated to be 60 m.
Deaerator operates at 0.4 bar g. Size the condensate pipe and calculate the back pressure
on the trap.
Solution:
Assume back pressure of 2 bar on the trap.
Steam at 10 bar g has saturation temperature of 184.130C and condensate has spe-
cific enthalpy of 781.6 kJ/kg (from Steam Tables). At 2 bar g, specific enthalpy of con-
Process Engineering Channel

densate and flash vapours will be 562.2 kl/kg and 2725.5 kJ/kg, respectively. If m is the
flash steam rate after the trap, enthalpy balance can be written as
2000 x 781.6 = m x 2725.5 + (2000 - m) 562.2
m = 202.8 kg/h
This represents 10.14 % flashing. Specific volume of flash steam at 2 bar g and
133.70C is 0.603 m3/kg.
Thus volumetric flow rate of flash steam will be 122.29 m3/h.
@ProcessEng

Form Fig. 5.17, pipe size for 25 m/s flash steam velocity is read between 40 and 50
mm NB. Select 50 mm NB condensate pipe, downstream of trap which could be of 25
mm size.
Friction loss in pipe = 0.1 x 60 = 6 kPa = 0.06 bar
Deaerator pressure = 0.4 bar
Elevation of deaerator = 10 m = 0.98 bar
 Process Design of Piping, Fluid Moving Devices and Flow Meters

Return Line Size, mm NB

500 400 350 300 250 200
100 000
15"
50 000 100

20 000

10 000

'(in"

moil

mil

200
Process Engineering Channel

0.5

Fig. 5.17 Steam Condensate Line Sizing Chart

(Reproduced with the Permission ofSpirax-Sarco Ltd., UK)

Total back pressure = 0.06 + 0.4 + 0.98 = 1.44 bar

@ProcessEng

Calculated back pressure is less than the assumed back pressure. Condensate pipe
design should therefore be satisfactory.

Refrigerants are another class of fluids which produce flash vapours on pressure
reduction of saturated liquids. Quantity of flash vapour normally varies from 15
to 40 %, depending on the refrigerant and the pressure difference across the
 130 Introduction to Process Engineering and Design

expansion valve. To avoid any problem of high pressure drop, the expansion
valve is situated close to the evaporator.
Charts, such as Fig. 5.17, are not readily available in literature for other fluids.
Hence, empirical equations for two phase flow are to be used for pressure drop
estimation.

5.10 TROUBLESHOOTING OF FLUID FLOW SYSTEMS

Utilities such as cooling water, steam, refrigeration, etc. are important to process
industry. Design of utility network should therefore be carried out carefully so
that no user equipment starves of any utility. This can also result in energy saving.
Apart from utilities, piping of process of fluids also require careful design.
Piping should neither offer excessive pressure drop nor should be overdesigned
as initial cost could be a deterrent.
In many instances, problems might arise in actual operation due to various
reason. Plant might be operated at a higher capacity thereby pumping capacity
might become limiting, higher pressure drop might be experienced in pipe line,
etc. In another example, fluid distribution in manifold piping might not be
satisfactory. In yet another instance, a new boiler of higher capacity is added and
steam from the new boiler is carried in the existing pipelines. In all these situations,
process engineer is required to evaluate the bottlenecks and carry out trouble-
shooting exercise.
Take the instance of installation of new higher capacity boiler. If pressure drop
calculations reveal high pressure drop in the existing pipeline, process engineer
can consider laying of another parallel pipeline from the boiler to nearest steam
consuming equipment. Alternately, steam at a higher pressure is conveyed from
the boiler if the existing pipeline rating permits its operation at higher pressure.
Instrument air manifold becomes a bottleneck in many situations as more in-
struments are added over a period of operation. Also, fluctuations in supply in-
strument air pressure could be a problem. After careful evaluation, installation of
an air receiver of adequate size near the plant may prove valuable.
For pumping system, upgradation of existing centrifugal pumps offers many
options. While evaluating the options, safety, reliability, ease of maintenance and
cost benefit analysis must be considered. Chaware el a/13 have dealt in detail the
Process Engineering Channel

upgrading options of a centrifugal pump. Impeller replacement, operation of two

pumps in parallel, installation of a bigger pump, change of a type of a pump, etc.
are the options that can be considered. Process engineer can contribute signifi-
cantly in troubleshooting.
@ProcessEng

Exercises

5.1 Answer the following:

(a) At 7 bar g, the leakage of steam through 3 mm, 6 mm and 12.5 mm diameter
holes amounts to 34,230 and 540 kg/h. respectively. One of the leakage figures
is a typographical error. Which figure? Why?
 Process Design of Piping, Fluid Moving Devices and Flow Meters ' 31

(b) A 2-stage reciprocating compressor is operating at 0.7 bar a inlet and 6.2 bar a
outlet pressure. If the pressure drop across the intercooler is 0.14 bar, the pressure
at the inlet of second stage will be approximately; (a) 3.38 bar a, (b) 2.69 bar a
or (c) 2.0 bar a.
(c) If volumetric flow rate and head of a centrifugal pump are proportional to
speed raised to power 0.8 and 1.5, respectively (for a given specific speed),
then power would be proportional to speed raised to power: (a) 3, (b) 2.3, (c)
2.0, (d) 1.5 or (e) 1.7.
(d) Pressure drop in a 150 mm NB diameter pipe in a well designed distribution
system is 0.07 bar due to water flowing at a certain rate. What will be the
pressure drop in 80 mm NB pipe for the same length and same flow rate?
(a) 4.4 bar (b) 1.62 bar (c) 1.1 bar (d) 0.55 bar (e) 0.276 bar or (e) 0.138 bar.
(e) An orifice type flow meter, installed on a liquid stream is coupled to a differen-
tial pressure (DP) transmitter and a flow recorder. Normal reading is 5 on a
0-10 square-root scale and 25 on a 0-100 linear scale. If the range of the DP
transmitter is doubled, the reading will be
(i) 2.5 on square-root scale and 6.3 on linear scale.
(ii) 2.25 on square-root scale and 12.5 on linear scale or
(iii) 7.1 on square-root scale and 50 on linear scale.
(f) For a centrifugal pump, power formula can be written as P = 80 ^ (d)3
where, P = power in hp
K = dimensionless pump constant
d = impeller diameter, in
To write this formula in metric units, P should be in kW and d should be in cm.
What will be the constant (instead of 80)?
5.2 A saturated gas mixture, obtained from a coal liquefaction plant after the acid removal
section, has composition of 38.2% H2,12.3% CO, 18% CO2, 31.0% CH4 and 0.5%
N2 (by mole) on dry basis. It is available at 120 kPa a and 60oC. It is cooled to 40oC
in a heat exchanger and sent to suction drum of a compressor. Condensate from the
drum is to be continuously pumped out with the help of a centrifugal pump. Calculate
the volume fraction of the gas mixture over the condensate and the artificial vapour
pressure using ideal gas low.

Table 5.15 Solubility of Cases9 in Water at I atm and 40°C

Gas Solubility, kg/lOO kg water

Process Engineering Channel

H2 0.000 1384
CO 0.002 075
co2 0.0973
ch4 0.001 586
N2 0.001 391

5.3 Natural gas is to be delivered through 0.6 m diameter steel pipe. Straight length of
@ProcessEng

pipe is 3 km. Equivalent length of fittings and valves of this pipe line is 300 m.
Desired flow rate of natural gas is 180 000 NirrVh. For the purpose, a centrifugal
compressor is installed at the Gas Gathering Station (GGS). Natural gas is to be
delivered at the plant at 313 K and 170 kPa a and it leaves the compressor at 313 K.
What pressure must be developed at the compressor discharge in order to achieve
this flow rate? Average molar mass of natural gas is 17.4 and its viscosity at 313 K
is 0.01 cP.
 Introduction to Process Engineering and Design

5.4 It is proposed to pump 5000 kg/h of acetic acid at 129.50C and 1.4 atm a pressure
from the reboiler of a distillation column to a hold up tank without cooling. If the
friction loss in the line between the reboiler and pump is 8 kPa and the density of
acetic acid is 1048 kg/m3, how far above the pump must the liquid level in the
reboiler be maintained to give a net positive suction head of 2.5 m? Friction loss in
discharge line is 40 kPa. Maximum liquid level of acetic acid above the discharge
point is 5 m. Pump efficiency is 60%. Calculate the power required to drive the
pump.
5.5 Performance of centrifugal pump on water is known. It can deliver 100 m3/h of
water at 80 m total head of water with 65% efficiency. By using Fig. 5.7, predict the
performance of this pump, if it is used to deliver the oil of viscosity 176 cSt (or 800
SSU) at the pumping temperature. Determine the head, capacity and power required
by this pump when it is used to deliver oil. Density of oil at pumping temperature is
800 kg/m3.
5.6 Design an Orifice meter based on the following data:
Name of fluid = Natural gas
Flow rate = 1000 NnrVh
Operating pressure = 1.35 atm a
Operating temperature = 380C
Average molar mass of natural gas = 17.2
Viscosity of natural gas = 0.01 cP at 380C
Inside diameter of pipe = 128.2 mm (5 in, SCH-40)
Specific heat ratio for natural gas =1.3
5.7 Design a venturi meter based on the data given in Example 5.21.
Mass flow rate through venturi meter is calculated by following equation.

Cv At I
m= ^ 2 gc App

where, Cv = Venturi coefficient = 0.98

A, = Throat area of venturi = —Dr

' 4 '
D, = Diameter of throat, m
13 = Ratio of diameter of throat to diameter of pipe
&■ = 1
Ap = Pressure drop measured by manometer. Pa
Process Engineering Channel

p = Density of flowing fluid, kg/m3

Angle of upstream cone of venturi meter is 30° and the same of downstream cone is
10°. Take 13=0.5.
Determine; (a) Throat diameter of venturi (b) Pressure drop and manometer reading
and (c) Lengths of upstream and downstream cones.
5.8 Determine the minimum and maximum flow rates of air at 40oC and at 1.5 atm a,
which can be measured by the rotameter of the dimension of tube and float of
@ProcessEng

rotameter, given in Fig. 5.15, except material of float is polypropylene.

Viscosity of air at 40oC = 1850 x K)"5 cP
Density of polypropylene = 905 kg/m3
Thickness of float = 2 mm
Calibrate the rotameter or find the different values of flow rates for the different
float positions.
 Process Design of Piping, Fluid Moving Devices and Flow Meters ' 33

5.9 In the Example 5.23 a rotameter is calibrated to measure the flow rate of water at
40oC. If the same rotameter is used for measuring flow rates of glycerine at 30oC
then what is the change in calibration?
Viscosity of glycerine at 30oC = 400 cP
Density of glycerine at 30oC = 1.25 kg/L

References

1. Sinnott, R. K., Coulson & Richardson's Chemical Engineering, Vol. 6, Asian Book
Private Ltd.. Revised 2ml Ed., New Delhi, 1998.
2. Perry, R. H. and Green D, Perry's Chemical Engineer's Handbook, 6lh Ed., McGraw-
Hill Book Company, USA, 1984.
3. Techo, R., Tinker, R. R. and R. E. James, J. Appl. Mech., 32, 1965, p. 443.
4. Ludwig, E. E., Applied Process Design for Chemical and Petrochemical Plants,
Gulf Publishing Company, Vol. 1, 3rd Ed., USA, 1999.
5. Flow of Fluids Through Valves, Fittings and Pipe, Published by Crane Co., New
York, USA, 1977.
6. Brown G. G., Unit Operations, John Wiley and Sons, Inc, USA, 1950.
7. Simpson, L. L., Chem. Engg., 75 (13), June 17, 1968, p. 190.
8. Hydraulic Institute Standards, 13,h Ed., Hydraulic Institute, USA.
9. Tsai, M. J., Chem. Engg., 89(15), July 26, 1982, p. 65.
10. McCabe, W. L., Smith, J. C. and Harriott P., Unit Operations of Chemical Engi-
neering, 6th Ed., McGraw-Hill Book Company, USA, 2001.
11. Coulson, J. M. and J. F. Richardson, Chemical Engineering, Vol. 1, Butter Worth-
Heinemann, 6,h Ed., UK, 1999.
12. Carrier System Design Manned: Refrigerants, Brines, Oil by Carrier Corporation,
USA, 1969.
13. Chaware, D. K. Shukla and R. B. Swamy, Hydrocarbon Processing, 84(5), 2005,
p. 47.
Process Engineering Channel
@ProcessEng
 Chapter
6

Process Design of

Heat Exchangers

6.1 SHELL AND TUBE HEAT EXCHANGER

Shell and tube heat exchangers are the most widely used equipments in chemical
industy. They are mostly used as heat transfer equipments but in a few cases they
are also used as Reactors, Falling Film Absorbers, etc. Sizes of various parts of
shell and tube heat exchangers like shell, tubes, tierods are standardized. Standards
developed by Tubular Exchanger Manufacturers Association, USA (TEMA) are
universally used for design of shell and tube heat exchangers. Equivalent Indian
Standard is IS: 4503. TEMA or IS: 4503 specify standard sizes of shell, tubes,
tierods, etc. and also maximum allowable baffle spacing, minimum tube sheet
thickness, baffle thickness, numbers of tierods required, etc. For mechanical design
and fabrication, in addition to TEMA standard, ASME Code Section VIII D1V.
I is used. In TEMA standard, shell and tube heat exchangers are classified in
three catagory;
(i) Class R covers heat exchangers which are used for severe duties in petro-
leum and related industries,
(ii) Class B covers the heat exchangers which are used in chemical process
industries not involving severe duties, and
Process Engineering Channel

(iii) Class C covers the heat exchangers which are used in commercial and in
less important process applications.
Most popular and reliable softwares used for the design of shell and tube heat
exchangers are of:
(i) HTRI: Heat Transfer Research Institute, USA
(ii) HTFS: Heat Transfer Fluid Flow Services, UK
@ProcessEng

(iii) BJAC: USA based company

(iv) HEI: Heat Exchange Institute, USA.
Design methods and equations used by these softwares are not available in open
literature. For the design of shell and tube heat exchanger involving fluid without
phase change, methods used by these softwares are based on Tinker's flow model.
 Process Design of Heat Exchangers

@0(2)0© 0000 © (36)

T*

=5

1
Q4) © 0
Internal Floating Head Heat Exchanger with Backing Ring, Type AES
(a)
32 2 3) 6 (T^

n
f

M &
Fixed Tube Sheet Heat Exchanger, Type BEM
(b)

o 19 20 21
Process Engineering Channel

Outside-Packed Floating Head Heat Exchanger, Type AEP

(c)

© <AX 3)0(5
@ProcessEng

yp

U Tube Heat Exchanger, Type CFU

(d)
 Introduction to Process Engineering and Design

© © d ©

Kettle Type Floating Head Reboiler, Type AKT

(e)

© 12 34

34 12 34 12 34 5

Exchanger with Packed Floating Tube sheet and Lantern Ring, Type AJW
(f)
Nomenclature of Parts of Various Shell and Tube Heat Exchangers
1. Stationary Head—Channel 14. Expansion Joint 27. Tie rods and Spacers
2. Stationary Head—Bonnet 15. Floating Tube sheet 28. Transverse Baffles or Sup-
3. Stationary Head Flage— 16. Floating Head Cover port Plates
Channel or Bonnet 17. Floating Head Flange 29. Impingement Plate
4. Channel Cover 18. Floating Head Split Backing 30. Longitudinal Baffle
5. Stationary Head Nozzle Ring 31. Pass Partition
6. Stationary Tube sheet 19. Split Shear Ring 32. Vent Connection
Process Engineering Channel

7. Tubes 20. Slip-on Backing Flange 33. Drain Connection

8. Shell 21. Floating Head Cover— 34. Instrument Connection
9. Shell Cover External 35. Support Saddle
10. Shell Flange-Stationary 22. Floating Tube sheet Skirt 36. Lifting Lug
Head End 23. Packing Box Flange 37. Support Bracket
II. Shell Flange-Rear Head End 24. Packing 38. Weir
12. Shell Nozzle 25. Packing Gland 39. Liquid Level Connection
13. Shell Cover Flange 26. Lantern Ring
@ProcessEng

Fig. 6.1 Different Types of Shell and Tube Heat Exchangers (Fig. N-2 of T EM A 8 Edition.
Reproduced with the Permission of the Tubular Exchanger Manufactures Association Inc.,
USA)
 Process Design of Heat Exchangers

6.2 DESIGN OF HEAT EXCHANGERS

6. 2.1 Various Parts of Shell and Tube Heat Exchangers

6.2.1.1 Shell

Shell is the costliest part of the heat exchanger. Cost of shell and tube heat
exchanger sensitively changes with change in the diameter of shell. As per the
TEMA standard, shell size ranges from 6 in (152 mm) to 60 in (1520 mm).
Standard pipes are available up to 24 in size (600 mm NB ). If shell size is greater
than 24 in, it is fabricated by rolling a plate.
Shell diameter depends on tube bundle diameter. For fixed tube sheet shell
and tube heat exchanger, the gap between shell and tube bundle is minimum,
ranging from 10 to 20 mm. For pull through floating head heat exchanger, it is
maximum, ranging from 90-100 mm.
Required shell diameter is determined by one of the following three methods:
(a) Based on the actual tube sheet layout drawing: All latest computer softwares
available for the design of heat exchangers use this method to find shell inside
diameter. Popular computer program, written in Autolips, is used to draw the
tube sheet layout. To draw the tube sheet layout or to find the tube bundle diam-
eter total six parameters are fixed, (i) Outside diameter (OD) of tube, (ii) Num-
bers of tube side passes, (iii) Tube pitch (center to center distance between adja-
cent tubes), (iv) Tube arrangement (triangular or square), (v) Total number of
tubes and (vi) Type of shell and tube heat exchanger (fixed tube sheet, U tube or
floating head).
(b) Use of standard tables: Based on actual tube sheet layout, standard tables
are prepared. These tables give the maximum number of tubes that can be accom-
modated in various standard sizes of shell ranging from 6 in (150 mm NB) to 120 in
(3000 mm NB), for the different numbers of tube side passes, different values of
tube pitch and size and for the different arrangements of tubes. Table 6.1 gives the
data on tube sheet layouts.

Table 6.1 Tube Sheet Tube Hole Count2 3

Process Engineering Channel

Table 6.1 (a) % in OD tubes on in square pitch

Shell ID TEMA Por S TEMA U

Number of Passes Number of Passes
mm in 1 2 4 6 2 4 6

203 8 55 48 34 24 52 40 32
254 10 88 78 62 56 90 80 74
@ProcessEng

305 12 140 138 112 100 140 128 108

337 13 X 178 172 146 136 180 164 148
387 15 X 245 232 208 192 246 232 216

438 17 X 320 308 274 260 330 312 292

489 19 X 405 392 352 336 420 388 368
(Contd.)
 138 Introduction to Process Engineering and Design

Tube Sheet Tube Hole Count (Conrd.)

Table 6.1 (a) (Conld.)

Shell ID TEMA PorS TEMA U

Number of Passes Number of Passes
mm in 1 2 4 6 2 4 6
540 21 X 502 484 442 424 510 488 460
591 23 X 610 584 536 508 626 596 562
635 25 700 676 618 600 728 692 644

686 27 843 812 742 716 856 816 780

737 29 970 942 868 840 998 956 920
787 31 1127 1096 1014 984 1148 1108 1060
838 33 1288 1250 1172 1148 1318 1268 1222
889 35 1479 1438 1330 1308 1492 1436 1388

940 37 1647 1604 1520 1480 1684 1620 1568

991 39 1840 1794 1700 1664 1882 1816 1754
1067 42 2157 2112 2004 1968 2196 2136 2068
1143 45 2511 2458 2326 2288 2530 2464 2402
1219 48 2865 2808 2686 2656 2908 2832 2764

1372 54 3656 3600 3462 3404 3712 3624 3556

1524 60 4538 4472 4310 4256 4608 4508 4426

Table 6.1 (b) / in OD tubes on %-in triangular pitch

Shell ID TEMA L or M TEMA P or S TEMA U

Number of passes Number of passes Number of
passes
mm in 1 2 4 6 1 2 4 6 2 4 6

114 4.5 14 14
152 6 30 30 24 22
203 8 64 48 34 24 34 32 16 18 32 24 24
254 10 85 72 52 50 60 62 52 44 64 52 52
305 12 122 114 94 96 109 98 78 68 98 88 78
i/
Process Engineering Channel

337 13 74 151 142 124 112 126 120 106 100 126 116 108
387 15 X 204 192 166 168 183 168 146 136 180 160 148
438 17 X 264 254 228 220 237 228 202 192 238 224 204
489 19 X 332 326 290 280 297 286 258 248 298 280 262
540 21 X 417 396 364 348 372 356 324 316 370 352 334
591 23 X 495 478 430 420 450 430 392 376 456 428 408
635 25 579 554 512 488 518 498 456 444 534 500 474
@ProcessEng

686 27 676 648 602 584 618 602 548 532 628 600 570
737 29 785 762 704 688 729 708 650 624 736 696 668
787 31 909 878 814 792 843 812 744 732 846 812 780
838 33 1035 1002 944 920 962 934 868 840 978 928 904
889 35 1164 1132 1062 1036 1090 1064 990 972 1100 1060 1008
(Contd.)
 Process Design of Heat Exchangers ' 39

Tube Sheet Tube Hole Count (Conrd.)

Table 6.1 (b) (Contd.)

Shell ID TEMA L or M TEMAP or S TEMAU

Number of passes Number of passes Number of
passes
mm in I 2 4 6 I 2 4 6 2 4 6

940 37 1304 1270 1200 1168 1233 1196 1132 1100 1238 1200 1152
991 39 1460 1422 1338 1320 1365 1346 1266 1244 1390 1336 1290
1067 42 1703 1664 1578 1552 1611 1580 1498 1464 1632 1568 1524
1143 45 1960 1918 1830 1800 1875 1834
1736 1708 1882 1820 1770
1219 48 2242 2196 2106 2060 2132 2100 1998 1964 2152 2092 2044

1372 54 2861 2804 2682 2660 2730 2684 2574 2536 2748 2680 2628
1524 60 3527 3476 3360 3300 3395 3346 3228 3196 3420 3340 3286
1676 66 4292 4228 4088 4044
1829 72 5116 5044 4902 4868
1981 78 6034 5964 5786 5740

2134 84 7005 6934 6766 6680

2286 90 8093 7998 7832 7708
2438 96 9203 9114 8896 8844
2743 108 11696 11618 1133611268
3048 120 1445914378 1408013984

Table 6.1 (c) % in OD tubes on I in square pitch

Shell ID TEMA P or S TEMA U

Number of Passes Number of Passes
mm in 1 2 4 6 2 4 6
152 6 12 12 — — 14 — —
203 8 28 26 16 12 28 24 12
254 10 52 48 44 24 52 44 32
305 12 80 76 66 56 78 72 70
Process Engineering Channel

337 13 X 104 90 70 80 96 92 90
387 15 X 136 128 128 114 136 132 120

438 17 X 181 174 154 160 176 176 160

489 19 X 222 220 204 198 224 224 224
540 21 X 289 272 262 260 284 280 274
591 23 X 345 332 310 308 348 336 328
635 25 398 386 366 344 408 392 378
@ProcessEng

686 27 477 456 432 424 480 468 460

737 29 554 532 510 496 562 548 530
787 31 637 624 588 576 648 636 620
838 33 730 712 682 668 748 728 718
889 35 828 812 780 760 848 820 816
(Conrd.)
 140 Introduction to Process Engineering and Design

Tube Sheet Tube Hole Count (Conrd.)

Table 6.1 (c) (Contd.)

Shell ID TEMA PorS TEMA U

Number of Passes Number of Passes
mm in 1 2 4 6 2 4 6

940 37 937 918 882 872 952 932 918

991 39 1048 1028 996 972 1056 1044 1020
1067 42 1224 1200 1170 1140 1244 1224 1212
1143 45 1421 1394 1350 1336 1436 1408 1398
1219 48 1628 1598 1548 1536 1640 1628 1602

1372 54 2096 2048 2010 1992 2108 2084 2068

1524 60 2585 2552 2512 2476 2614 2584 2558

Table 6.1 (d) in OD tubes on I in triangular pitch

Shell ID TEMA L or M TEMA P or S TEMA U

Number of passes Number of passes Number of
passes
mm in 1 2 4 6 I 2 4 6 2 4 6
114 4.5 14 14
152 6 26 26 24 22 14 14 — — 14 12 10
203 8 42 40 26 24 31 26 16 12 32 24 24
254 10 73 66 52 44 56 48 42 40 52 48 40
305 12 109 102 88 80 88 78 62 68 84 76 74
337 1/
13 /4 136 128 112 102 121 106 94 88 no 100 98
387 15 X 183 172 146 148 159 148 132 132 152 140 136
438 17 X 237 228 208 192 208 198 182 180 206 188 182
489 1/
19 74 295 282 258 248 258 250 228 220 226 248 234
540 1/
21 74 361 346 318 320 320 314 290 276 330 316 296
591 1/
23 74 438 416 382 372 400 384 352 336 400 384 356
635 25 507 486 448 440 450 442 400 392 472 440 424

686 27 592 574 536 516 543 530 488 468 554 528 502
737 29 692 668 632 604 645 618 574 556 648 616 588
Process Engineering Channel

787 31 796 774 732 708 741 716 666 648 744 716 688
838 33 909 886 836 812 843 826 760 740 852 816 788
889 35 1023 1002 942 920 950 930 878 856 974 932 908
940 37 1155 1124 1058 1032 1070 1052 992 968 1092 1056 1008
991 39 1277 1254 1194 1164 1209 1184 1122 1096 1224 1180 1146
1067 42 1503 1466 1404 1372 1409 1378 1314 1296 1434 1388 1350
1143 45 1726 1690 1622 1588 1635 1608 1536 1504 1652 1604 1560
@ProcessEng

1219 48 1964 1936 1870 1828 1887 1842 1768 1740 1894 1844 1794
1372 54 2519 2466 2380 2352 2399 2366 2270 2244 2426 2368 2326
1524 60 3095 3058 2954 2928 2981 2940 2932 2800 3006 2944 2884
1676 66 3769 3722 3618 3576
1829 72 4502 4448 4324 4280
1981 78 5309 5252 5126 5068
(Contd.)
 Process Design of Heat Exchangers ' 41

Tube Sheet Tube Hole Count (Contd.)

Table 6.1 (d) {Contd.)

Shell ID TEMA L or M TEMA P or S TEMA U

Number of passes Number of passes Number of
passes
mm in 1 2 4 6 1 2 4 6 2 4 6

2134 84 6162 6108 5954 5900

2286 90 7103 7040 6898 6800
2438 96 8093 8026 7848 7796
2743 108 1026010206 9992 9940
3048 120 12731 12648 1245012336

Table 6.1 (e) 1 in OD tubes on 1 / in square pitch

Shell ID TEMA PorS TEMA U

Number of Passes Number of Passes
mm in 1 2 4 6 2 4 6
203 8 17 12 8 12 14 8 6
254 10 30 30 16 18 30 24 12
305 12 52 48 42 24 44 40 32
337 13 X 61 56 52 50 60 48 44
387 15 X 85 78 62 64 80 72 74

438 17 X 108 108 104 96 104 100 100

489 19 X 144 136 130 114 132 132 120
540 21 X 173 166 154 156 172 168 148
591 23 X 217 208 194 192 212 204 198
635 25 252 240 230 212 244 240 230

686 27 296 280 270 260 290 284 274

737 29 345 336 310 314 340 336 328
787 31 402 390 366 368 400 384 372
838 33 461 452 432 420 456 444 440
889 35 520 514 494 484 518 504 502
Process Engineering Channel

940 37 588 572 562 548 584 576 566

991 39 661 640 624 620 664 644 640
1067 42 776 756 738 724 764 748 750

1143 45 900 882 862 844 902 880 862

1219 48 1029 1016 984 972 1028 1008 1004
@ProcessEng

1372 54 1310 1296 1268 1256 1320 1296 1284

1524 60 1641 1624 1598 1576 1634 1616 1614

{Contd.)
 | 142 Introduction to Process Engineering and Design

Tube Sheet Tube Hole Count (Contd.)

Table 6.1 (f) I in OD tubes on I / in triangular pitch

Shell ID TEMA L or M TEMA P or S TEMA U

Number of passes Number of passes Number of
passes
mm in 1 2 4 6 1 2 4 6 2 4 6
203 8 27 26 8 12 18 14 8 12 14 12 6
254 10 42 40 34 24 33 28 16 18 28 24 24
305 12 64 66 52 44 51 48 42 44 52 40 40
337 1/
13 /4 81 74 62 56 73 68 52 44 64 56 52
387 15 1/ 106 106 88 92 93 90 78 76 90 80 78
/4
438 17 X 147 134 124 114 126 122 112 102 122 112 102
489 19 X 183 176 150 152 159 152 132 136 152 140 136
540 21 X 226 220 204 186 202 192 182 172 196 180 176
591 23 X 268 262 236 228 249 238 216 212 242 224 216
635 25 316 302 274 272 291 278 250 240 286 264 246

686 27 375 360 336 324 345 330 298 288 340 320 300
737 29 430 416 390 380 400 388 356 348 400 380 352
787 31 495 482 452 448 459 450 414 400 456 436 414
838 33 579 554 520 504 526 514 584 464 526 504 486
889 35 645 622 586 576 596 584 548 536 596 572 548

940 37 729 712 662 648 672 668 626 608 668 636 614
991 39 808 792 744 732 756 736 704 692 748 728 700
1067 42 947 918 874 868 890 878 834 808 890 856 830
1143 45 1095 1068 1022 1000 1035 1008 966 948 1028 992 972
1219 48 1241 1220 1176 1148 1181 1162 1118 1092 1180 1136 1100
1372 54 1577 1572 1510 1480 1520 1492 1436 1416 1508 1468 1442
1524 60 1964 1940 1882 1832 1884 1858 1800 1764 1886 1840 1794
1676 66 2390 2362 2282 2260
1829 72 2861 2828 2746 2708
1981 78 3368 3324 3236 3216

2134 84 3920 3882 3784 3736

Process Engineering Channel

2286 90 4499 4456 4370 4328

2438 96 5144 5104 4986 4936
2743 108 6546 6494 6360 6300
3048 120 8117 8038 7870 7812

In
Table 6.1 (g) I ^ tubes on I % in square pitch
@ProcessEng

Shell ID TEMA P or S TEMA U

Number of Passes Number of Passes
mm in 12 4 6 2 4 6
203 8 12 12 4 0 4 4 6
254 10 21 12 8 12 12 8 12
{Contd.)
 Process Design of Heat Exchangers ' 43

Tube Sheet Tube Hole Count (Conrd.)

Table 6.1 (g) (Conld.)

Shell ID TEMA PorS TEMA U

Number of Passes Number of Passes
mm in i 2 4 6 2 4 6
305 12 29 28 16 18 26 20 12
337 13 X 38 34 34 24 36 28 15
387 15 % 52 48 44 48 44 44 32

438 17 K 70 66 56 50 60 60 56
489 19 % 85 84 70 80 82 76 79
540 21 % 108 108 100 96 100 100 100
591 23 K 136 128 128 114 128 120 120
635 25 154 154 142 136 154 148 130

686 27 184 180 158 172 176 172 160

737 29 217 212 204 198 212 204 198
787 31 252 248 234 236 242 240 234
838 33 289 276 270 264 280 280 274
889 35 329 316 310 304 324 312 308

940 37 372 368 354 340 358 352 350

991 39 420 402 402 392 408 400 392
1067 42 485 476 468 464 480 476 464
1143 45 565 554 546 544 558 548 550
1219 48 653 636 628 620 644 628 632

1372 54 837 820 812 804 824 808 808

1524 60 1036 1028 1012 1008 1028 1016 1008

Table 6.1 (h) I j/^ in OD tubes on I ^ in triangular pitch

Shell ID TEMA L or M TEMA P or S TEMA U

Number of Passes Number of Passes Number of
Passes
mm in 1 2 4 6 1 2 4 6 2 4 6
Process Engineering Channel

203 8 15 10 8 12 13 10 4 0 6 4 6
254 10 27 22 16 12 18 20 8 12 14 12 12
305 12 38 36 26 24 33 26 26 18 28 20 18
337 13 1/ 55 44 42 40 38 44 34 24 34 28 30
/4
387 15 1/ 66 64 52 50 57 58 48 44 52 48 40
/4
438 17 1/ 88 82 78 68 81 72 62 68 72 68 64
/4
489 19 1/ 117 106 98 96 100 94 86 80 90 84 78
74
@ProcessEng

540 21 1/ 136 134 124 108 126 120 116 102 118 112 102
74
591 23 1/ 170 164 146 148 159 146 132 132 148 132 120
74
635 25 198 188 166 168 183 172 150 148 172 160 152
(Conrd.)
 Introduction to Process Engineering and Design

Tube Sheet Tube Hole Count (Conrd.)

Table 6.1 (h) (Conrd.)

Shell ID TEMA L or M TEMA P or S TEMAU

Number of Passes Number of Passes Number of
Passes
mm in 12 4 6 12 4 6 2 4 6

686 27 237 228 208 192 208 206 190 180 200 188 180
737 29 268 266 242 236 249 238 224 220 242 228 216
787 31 312 304 284 276 291 282 262 256 282 264 250
838 33 357 346 322 324 333 326 298 296 326 308 292
889 35 417 396 372 364 372 368 344 336 362 344 336

940 37 446 446 422 408 425 412 394 384 416 396 384
991 39 506 490 472 464 478 468 442 432 472 444 428
1067 42 592 584 552 544 558 546 520 512 554 524 510
1143 45 680 676 646 632 646 634 606 596 636 624 592
1219 48 788 774 736 732 748 732 704 696 736 708 692

1372 54 1003 980 952 928 962 952 912 892 946 916 890
1524 60 1237 1228 1188 1152 1194 1182 1144 1116 1176 1148 1116
1676 66 1520 1496 1448 1424
1829 72 1814 1786 1736 1724
1981 78 2141 2116 2068 2044

2134 84 2507 2470 2392 2372

2286 90 2861 2840 2764 2744
2438 96 3275 3246 3158 3156
2743 108 4172 4136 4046 4020
3048 120 5164 5128 5038 5000
(Reproduced with the Permission of McGraw-Hill Education. USA)

(c) Use of approximate equations: Approximate equations are available in

literature to find the shell diameter or to find the tube bundle diameter. One of
such equations4 is given as follows:
Process Engineering Channel

N, "i
Db = d0 (6.1)
c
i

where, Db = Tube bundle diameter, mm

d0 = Tube OD, mm
A, = Total number of tubes
@ProcessEng

tube pitch
kj and tij are constants, values of which depend on ratio
d„ tube OD
arrangement of tubes and number of tube side passes.
Use Tables 6.2 and 6.3 for finding constants of Eq. (6.1).
 Process Design of Heat Exchangers ' 45

Table 6.2 Constants for Eq. (6.1)

A. For P/d,, = 1.25. Triangular Pitch

No. of tube side passes 1 2 4 6 8

k, 0.319 0.249 0.175 0.0743 0.0365
n, 2.142 2.207 2.285 2.499 2.675

Table 6.3 Constants for Eq. (6.1)

B. For P,/d0 = 1.25, Square Pitch

No. of tube side passes 1 2 4 6 8

it, 0.215 0.156 0.158 0.0402 0.0331
n, 2.207 2.291 2.263 2.617 2.643

Equation (6.1) can be used for fixed tube sheet type and floating head shell and
tube type heat exchangers.
But for U-tube heat exchangers, following equation can be used.

Np-
Db - d0\ (6.2)
q /
Dh
where, N, = N, (6.3)
Pi
TV, = Number of lube holes on lube sheet
After finding tube bundle diameter shell ID (Inside diameter) D, can be deter-
mined by following equation.

A = Db + C (6.4)
where, C = Clearance between shell ID and Dh
C = 10 to 20 mm for fixed tube sheet and U-tube
C = 50 to 80 mm for split-ring floating head
C = 90 to 100 mm for pull through floating head

6.2.1.2 Shell Side Pass Partition Plate

Process Engineering Channel

Single pass shell is used in the most of the cases. Two pass shell is rarely used
and is recommended where shell and tube temperature difference is unfavorable
for the single pass. For such cases normally two or more heat exchangers, con-
nected in series, are recommended. Shell side pass partition plate is not provided
to improve shell side heat transfer coefficient but it is provided to avoid the unfa-
vourable temperature difference or to avoid the cross of temperatures between
@ProcessEng

hot fluid and cold fluid.

Example 6.0
Hot oil is to be cooled from 450C to 370C by cooling water. Cooling water will enter at
320C and leave at 40oC. Minimum driving force required for heat transfer in shell and
tube heat exchanger is 3 to 5 0C. Hence, for this case 1-1 shell and tube heat exchanger
 Introduction to Process Engineering and Design

can be selected. But it will provide poor heat transfer coefficient and may require large
heat transfer area. 1-2 shell and tube heat exchanger cannot be selected for this case
because of the occurrence of hypothetical temperature cross between hot and cold
fluids. 2-2 shell and tube heat exchanger can be selected. 2-2 heat exchanger will
provide higher heat transfer coefficient than 1-1 heat exchanger.

6.2.1.3 Baffles

There are two functions of baffles.

(i) Baffles are used in shell to direct the fluid stream across the tubes to in-
crease the velocity of shell side flow and thereby to improve the shell side
heat transfer coefficient. In other words baffles are used in shell to increase
the turbulence in shell side fluid.
Note: This function is useful only if there is no phase change in shell side
fluid
(ii) Baffles indirectly support the lubes and thereby reduce the vibration in tubes.
If shell side liquid velocity is higher; say more than 3 m/s, vibration analy-
sis calculations should be carried out to check whether baffle spacing is
sufficient or not. Similarly, for very high velocity of gas or vapour and also
for the higher baffle spacing (higher than shell ID), vibration analysis cal-
culation must be carried out to check the baffle spacing. Vibration analysis
calculations are given in TEMA standard.
Different types of baffles are used in shell and tube heat exchangers; (i) Seg-
mental baffle, (ii) Nest baffle, (iii) Segmental and Strip baffle (iv) Disc and
Doughnut baffle, (v) Orifice baffle (vi) Dam baffle, etc. Figure 6.2 shows vari-
ous types of baffles.
Most widely used type of baffle is segmental baffle. Other types of baffles like
nest baffle, segmental and strip baffle and disc and doughnut baffle provide less
pressure drop for the same baffle spacing but provide lower heat transfer coeffi-
cients as compared to segmental baffle. Examples: Situation when other types of
baffles might be used.
(a) For shell and tube heat exchangers shell side pressure drop controls the
overall design. For example, intercoolers of compressors and heat exchang-
Process Engineering Channel

ers used in very high vacuum system. In intercoolers of compressors maxi-

mum allowable shell side pressure drop may be as low as 3.45 kPa. For
such cases different types of shells are also used. Split flow (G shell) or
divided flow (J shell) designs provide low shell side pressure drop com-
pared to commonly used single pass ( E shell). Refer Fig. 6.3
(b) For shell and tube heat exchanger in which boiling or condensation is car-
@ProcessEng

ried out on shell side. In such a case baffles are required only to reduce the
vibrations in tubes.
For other type of baffles (other than segmental baffle) correlations for finding
heat transfer coefficient and pressure drop are not easily available in open litera-
ture.
 Process Design of Heat Exchangers

oo
'ooooooN
OOOOOO \l oooooo
loooo oooo oooooo oo)
(oooo oooo \ooooooool
OOOOOO/\oooooo,
\000 000/

Without Trim Base

(a) Segmental Baffles with Horizontal Cut

00
'000 000
oooooo \ 000 000
00000000)
,00000000
oooooo / oooooo
>000000,
00

(b) Segmental and Strip Baffles

000 000
00
0 (oooo)
v „ \0000J
000 000

(e) Disc and Doughnut Baffles

^OO
OOOOO Tubes
OOOOOO A h
00 00 o o o
00 00 oo 00
OOOOOO/
\p o o o 0 9/ \ i
T o o^

(d) Orifice Baffles (e) Nest Baffle

o
o
qOOQ- 0° OQ
OOO OOO qOOQ 0 0000
'0oO foooo oooo) \ O 00
S00 lOOOO 00001 0000 0
O 00
0
O
OoOTTQ OOOOOO 0000 \o 0 0
O /
sOOO OOO/ 0000 0/ 0000
0000
- o or- 0000 0000
o
(f) Dam Baffle (g) Horizontal Cut (h) Segmental with Vertical Cut
with Trim Base
Process Engineering Channel

(f), (g), and (h); Baffles for Condensers

Fig. 6.2 Different Types of Baffles used in Shell and Tube Heat Exchangers2
(Reproduced with the Permission of McGraw-Hill Education, USA)

Segmental baffle is made by cutting the circular metal disc. Segmental baffles
are specified in terms of % baffle cut.
% Baffle cut = h/d x 100 (6.5)
@ProcessEng

where, h = Height of segment removed

D = Diameter of circular metal disc from which segment is removed
= ID of shell - 2 x Clearance
% Baffle cut ranges from 15 to 45%. If there is no phase change on shell side
fluid, then decrease in % baffle cut increases shell side heat transfer coefficient.
Decrease in window area results in increase in window velocity but at the ex-
pense of pressure drop. 20 to 25% Baffle cut is found to be common in use.
 148 Introduction to Process Engineering and Design

(b)

(c)

Fig. 6.3 (a) One Pass Shell (E Shall) (b) Split Flow (G Shell) (c) Divided Flow (J Shell)

Baffle outside diameter is always less than shell inside diameter. Certain clear-
ance between baffle OD and shell ID is provided to facilitate removal and inser-
tion of lube bundle for maintenance. Recommended clearance between shell ID
and baffle OD is as follows.

Table 6.4 Clearance Between Shell and Segmental Baffle

Shell ID Clearance (Shell ID - Baffle OD)

Process Engineering Channel

Standard pipe shell 6 in to 24 in (150 mm to 600 mm) 1.6 mm

Plate shell 6 in to 25 in (150 mm to 625 mm) 3.2 mm
Plate shell 27 in to 42 in (675 mm to 1050 mm) 4.8 mm

If shell is fabricated from plate then it may not be a perfect cylinder. Hence, for
plate shell, more clearance is permitted. For heat exchanger without phase change,
increase in clearance between shell ID and baffle OD could mean decrease in
@ProcessEng

shell side heat transfer coefficient due to leakage. Fraction of shell side fluid
flowing through this clearance is not utilized for heat transfer. Hence this clear-
ance, if it is more than recommended value, is undesirable.
In kettle type reboiler, full baffle (with 0% baffle cut) is used, as in this type of
heat exchanger extra space is available for the flow of shell side liquid.
 Process Design of Heat Exchangers

In case of horizontal inclined condenser, segmental baffles with horizontal cut

should not be used as they create resistance to the flow of condensate. Hence, in
this case there are two options; (i) Use segmental baffles with vertical cut
(Fig. 6.2 (h)) or (ii) Use segmental baffles with horizontal cut but their base must
be trimmed (Fig. 6.2 (g)).
Tube holes are made in baffle. Diameter of tube hole in baffle is kept higher
than tube OD. Normally this clearance is less than 0.8 mm.
Thickness of baffle depends on size of shell and spacing between baffles. For
the given size of shell, thickness of baffle increases with increase in baffle spac-
ing. It can be determined from the table given in TEMA standard. As per Kern5,
baffle spacing ranges from 0.2 to 1 limes shell ID. Lesser baffle spacing gives
higher heat transfer coefficient but at the expense of higher pressure drop. Opti-
mum baffle spacing is in between 0.3 to 0.5 times shell inside diameter.

6.2.1.4 Tube

Tube size range from 1/4 in (6.35 mm) to 2.5 in (63.5 mm ) in shell and tube heat
exchanger. Data for standard tubes are given in TEMA standard and Table 11.2
of Ref. 2. For the standard tubes, its size is equal to outer diameter of tube. Thick-
ness of standard tubes are expressed in BWG (Birmingham Wire Gauge). In-
crease in the value of BWG means decrease in tube thickness. For no phase
change heat exchangers and for condensers, 3/4 in (19.05 mm OD) tube is widely
used in practice. While for reboiler I in (25.4 mm OD) tube size is common.
Tubes are available in standard lengths like 6 ft (1.83 m), 8 ft (2.44 m), 12 ft (3.66
m), 16 ft (4.88 m) and 6 m.

6.2.1.5 Tube Side Pass Partition Plate

Tube side passes are provided to decrease the tube side flow area and to increase
tube side fluid velocity thereby to improve the tube side heat transfer coefficient,
at the expense of pressure drop. This is true only if there is no phase change on
tube side. Hence, more number of lube side passes are recommended only if
there is no change in the phase of tube side fluid.
For example, at the design stage, if the number of lube side passes are in-
creased from one to two, then for the given volumetric flow rate, flow area be-
comes half and velocity becomes double. Since, tube side heat transfer coeffi-
Process Engineering Channel

0 8
cient, h oc u. (where u. is tube side fluid velocity), on increasing number of
tube side passes from 1 to 2, /?, nearly becomes 1-7 times. But, A/?, oc u, , so the
pressure drop increases by 6.96 times. Increase in h/ means decrease in heat transfer
area required and decrease in fixed cost. Increase in A/?, means increase in power
required for pumping the tube side fluid and increase in operating cost. Hence,
ideally optimum number of tube side passes must be decided.
@ProcessEng

Tube side passes are very common and are advantageously used for improv-
ing tube side heat transfer coefficient. These passes can be achieved in many
ways by locating partition plates in channel covers. Figure 6.4 gives different
designs for achieving desired tube passes.
 150 Introduction to Process Engineering and Design

Single Pass Two Pass Four Pass Six Pass Eight Pass

V§7
Ka) 2(a) 3(a) 4(a) 5(a)

o 0 0
Kb) 2(b) 3(b) 4(b) 5(b)

O 0
1(c) 2(c) 3(c) 4(c) 5(c)

o
1(d) 2(d) 3(d) 4(d) 6(d)

o 0
1(e) 2(e) 3(e) 4(e) 6(e)

0 m
Kf) 2(f) 3(f) 4(f) 6(f)
3
F'g- 6.4 Nozzle Orientation Designs for Tube Side Passes

6.2.1.6 Tie Rods

Baffles are supported by tie rods. Tie rods are made from solid metal bar. Nor-
mally four or more tie rods are required to support the baffles. Diameter of tie rod
is less than the diameter of tube. Diameter and number of tie rods required for
given shell diameter are specified by TEMA standard and IS: 4503.

6.2.1.7 Spacers

Spacers (Fig. 6.5) are used to maintain the space between baffles. Spacers are the
pieces of pipes or in the most of the cases they are the pieces of extra available
tubes. Spacers are passed over the tie rods and because of them baffles do not
slide over tie rods under the effect of the force of fluid. Hence, spacers fix the
location of baffles and maintain the space between them. Length of spacer is
Process Engineering Channel

equal to space between the baffles.

Baffles
X X
@ProcessEng

0*- 0 ^
Spacer
Tie rod

Tube Plate
Fig. 6.5 Baffle Spacer Detail
 Process Design of Heat Exchangers

6.2.1.8 Tube Sheet

Tubes and one end of tierods are attached to tube sheet (also called tube plate).
Hence, entire load of tube bundle is transferred to one or two tube sheets. In U-
tube shell and tube heat exchanger (as shown in Fig. 6.1(d), type CFU or
Fig. 6.1(e), type AKT) only one tube sheet is used. While in fixed tube sheet shell
and tube heat exchanger, two tube sheets are used. One surface of tube sheet is
exposed to tube side fluid and other surface is exposed to shell side fluid. This
point is very important in the selection of material for tube sheet and also in
determining tube sheet thickness.
Tube to tube sheet joints are two types; (a) Expanded joint and (b) Welded
joint as shown in Fig. 6.6.

Tube Sheet

Grooves Tube Wall

(a) Expanded Type (b) Welding Joint

Fig. 6.6 Tube to Tube Sheet Joint

In expanded type joint, tube holes are drilled in a tube sheet with a slightly
greater diameter than the tube OD. Two or more grooves are cut in the wall of
each hole. The tube is placed inside the tube hole and a tube roller is inserted
into the end of the tube. Roller is slightly tapered. On application of the roller,
tube expands and tube material flows into grooves and forms an extremely light
seal. Welding joint is used only for the cases where leakage of fluid can be
disasterous.
Detailed method for calculating tube sheet thickness is given in TEMA and in
Process Engineering Channel

IS: 4503. Minimum required tube sheet thickness is also specifed in the same.
Simplified equation is also available for calculating tube sheet thickness.

i
0.25 P
t = FG (6.6)

where, t = Effective tube sheet thickness, mm

@ProcessEng

F = constant (1 for fixed tube sheet and 1.25 for U-tube)

P = Design pressure, kPa
f= Allowable stress of tube sheet material at design temperature, kPa
G = Mean diameter of gasket, mm
 Introduction to Process Engineering and Design

Then thickness of tube sheet T is given by equation

T> {t+ depth of pass partition groove + tube side corrosion allowance +
shell side corrosion allowance)
Also T > Minimum thickness specified in the standard

6.2.1.9 Sealing Strip

It is a shell side component. Sealing strips are attached on the inside surface of
shell as shown in Fig. 6.7 throughout the length of shell.

oo
ooooo
/ ■ J •_ oooooo
':' -
-j c O G O U C_C: - o
)<:
or c
QOOOOO

Sealing Strip

Fig. 6.7 Sealing Strips

There are two functions of sealing strips.

(i) Sealing strips reduce the amount of bypass stream of shell side fluid flow-
ing through the clearance between shell inside diameter and tube bundle
diameter and thereby improve the shell side heat transfer coefficient. (This
is valid only if there is no phase change of shell side fluid).
(ii) Sealing strips also make the removal of tube bundle from the shell easy.
Hence, they are also known as sliding strips.
In Kern's method, it is assumed that entire shell side fluid is flowing across the
tube bundle and between the baffles. Actually, shell side fluid is flowing in vari-
ous ways. In all latest methods of process design, shell side fluid flow is divided
in five streams. Among these streams, one of the streams is flowing through the
clearance between shell ID and tube bundle. This clearance is significant in case
of pull through floating head heat exchanger (about 90 to 100 mm). In addition,
this clearance provides low pressure drop path for shell side fluid. Hence, actual
fraction of shell side fluid bypassed through this clearnace is considerably higher.
Sealing strip blocks the gap between bundle and shell and thereby reduce the
Process Engineering Channel

amount of this bypass stream considerably. In case of pull through floating head
heat exchanger, all latest computer programes, like HTRI, suggest the use of
sealing strip. Also in such programs shell side heat transfer coefficient is a func-
tion of diamension and numbers of sealing strips provided. Kern's method is not
recommended for use to predict heat transfer coefficient and pressure drop for
pull through floating head heat exchanger.
@ProcessEng

6.2.1.10 Expansion Joint

Expansion joint is attached to shell wall. In this case shell is made from two pipe
pieces. Two pipe pieces are joined together by an expansion joint as shown in
Fig. 6.8.
 Process Design of Heat Exchangers

(a) Flat Plates (b) Flanged only Heads (c) Flared Shell or
Pipe Segments

(\

(d) Formed (e) Flanged and (t) Toroidal

Heads Fined Heads

W
UU ^J*

(g) Bellows Type (h) Bellows Type with (i) High Pressure
Reinforcing Rings Toroidal Bellows
and Insulation Cover
Fig. 6.8 Expansion Joints2
(Reproduced with the Permission of McGraw-Hill Education. USA)

Expansion joint is used in fixed tube heat exchanger to permit the differential
thermal expansion or contraction between shell and lubes which otherwise is not
permitted by fixed tube sheet heat exchanger. Differential thermal expansion be-
tween shell and tube is significant if there is a large temperature difference be-
tween temperature of shell material and temperature of tube material during op-
Process Engineering Channel

eration or if tube material and shell material are different. For the given case of
fixed tube sheet heat exchanger, whether an expansion joint is required or not
can be determined by calculations given in TEMA. If expansion joint is not pro-
vided in fixed tube sheet heat exchanger, then fixed tube sheet does not permit
the unequal expansion or contraction between shell and tube and it can result in
the development of thermal stress across the tube sheet. If this thermal stress is
@ProcessEng

higher than permissible value, then it may develop a crack in tube sheet, and can
result in leakage at tube to tube sheet joint. Other options, available to avoid the
development of thermal stress in the tube sheet are use of either U tube heat
exchanger or floating head heat exchanger.
 154 Introduction to Process Engineering and Design

6.2.2 Advantages and Disadvantages of Different Type of

Shell and Tube Heat Exchangers Over Each Other

6.2.2.1 Advantages of U-tube and Floating Head Heat

Exchangers (Figs 6.1 (a) and 6.1 (d)) Over Fixed
Tube Sheet Heat Exchangers are

(i) Maintenance and cleaning of tube bundle is easier. In U-tube and floating
head heat exchanger entire tube bundle can be easily taken out for cleaning
and maintenace. While the same is not possible in fixed tube sheet heat
exchanger.
(ii) U-tube and floating head heat exchangers permit the differential thermal
expansion or contraction between shell and tube. Therefore, use of expan-
sion joint is not required in U-tube and floating head heat exchangers.

6.2.2.2 Disadvantages of U-tube and Floating Head Heat

Exchangers Over Fixed Tube Sheet

(i) For a given heat duty, U-tube and floating head heat exchangers are costlier
than fixed tube sheet heat exchangers because of the following reasons.
(a) For the same number of tubes, tube arrangement and tube pitch, shell
sizes required by U-tube and floating head heat exchangers are higher
than the same required by fixed tube sheet heat exchangers. In U-tube
heat exchanger, minimum bend radius of U-tube is 1.5da, hence in
central portion of tube bundle, tubes cannot be provided. In floating
head heat exchanger more clearnace between shell ID and tube bundle
diameter (50 to 100 mm) is required.
(b) In case of cooling or heating of shell side fluid (no phase change) heat
transfer coefficients obtained in U-tube and floating head heat exchang-
ers for the given heat duty are less than the same obtained in fixed tube
sheet heat exchangers as bypassing area is higher in case of U-tube or
floating head as compared to fixed tube sheet heat exchanger.

6.2.2.3 Advantages and Disadvatages of U-tube Heat

Exchanger Over Floating Head Heat Exchanger
Process Engineering Channel

Advantage:
Fixed cost of U-tube heat exchanger is always less than the same of floating head
heat exchanger for the given duty.
Disadvatages:
(i) In U-lube, tube material becomes weak in bending portion, hence use of U-
tube heat exchanger is not recommended for severe conditions. While for
@ProcessEng

the same conditions floating head heat exchanger can be used.

(ii) In U-tube heat exchanger number of tube side passes are fixed (two). It
reduces the flexibility in design calculations.
(iii) U-tube heat exchanger is not recommended to use for tube side dirty fluid.
As it is difficult to remove dirt from U-tube. While floating head heat ex-
changer can be used where both shell side fluid and tube side fluid are dirty.
 Process Design of Heat Exchangers

6.2.2.4 Floating Head Heat Exchangers are of Two Types

(a) Split-ring floating head heat exchanger

(b) Pull through floating head heat exchanger.
Split-ring floating head heat exchanger is widely used in the chemical process
industries (Fig. 6.1 (a)). With this type split backing ring is provided. Advantages
and disadvantages of this heat exchanger over pull through floating head heat
exchanger are as follows.
Advantage:
Compared to pull through floating head heat exchanger, less diameter is required
for shell to accommodate the same number of tubes.
Disadvatages:
More maintenance time is required. In maintenance, shell cover is removed first,
then the split backing ring, then floating head cover and finally tube bundle is
removed from the stationary end.
Pull through floating head heat exchanger is the costliest type of shell and
tube heat exchanger because it requires largest shell diameter for the given num-
bers of tubes. With this heat exchanger it is possible to remove the entire tube
bundle including floating head assembly from the stationary end.

6.2.3 Different Types of TEMA Designations

In TEMA standard different types of shell and tube heat exchangers are desig-
nated by three letters. First letter indicates type of front head, second letter indi-
cates type of shell and third indicates type of rear head. Different types of TEMA
designations are shown in Fig. 6.9.
For example, BEM shell and tube type heat exchanger means bonnet type (B
type) front head, single pass (E type) shell and stationary head with fixed tube
sheet (M type) rear head. BFL type shell and tube heat exchanger means bonnet
type front head, two pass shell with longitudinal baffle (F type shell) and station-
ary head with fixed tube sheet and removable flat cover (L type rear head).

6.3 GENERAL DESIGN METHOD FOR SHELL AND

TUBE HEAT EXCHANGER
Process Engineering Channel

6.3.1 Calculation of Heat Duty

(a) For cooling or heating or for no phase change, heat duty is calculated by
equation
0 = mCp At (6.7)
where, in = Mass flow rale of fluid, kg/s
0
Cp = Specific heat of fluid, in kJ/(kg • C)
@ProcessEng

At = Temperature difference to be carried out, 0C

0 = Heat duty required, kW
(b) For condensation with subcooling

0 = mA + mCL At (6.8)
 Introduction to Process Engineering and Design

Front End Rear End

Shell Types
Stationary Head Types Head Types

neJla-
Jl
L X
A Fixed Tube Sheet Like
"A" Stationary Head
One Pass Shell
"TLT8-
Channel and X
Removable Cover M
T Fixed Tube Sheet Like
Two Pass Shell "B" Stationary Head
with Longitudinal
Baffle
B
N
Fixed Tube sheet Like
G "C" Stationary Head
Bonnet
(Integral Cover) Packing
Split Flow

i
Outside Packed
Removable JE L
Tube Floating Head
C
Bundle H Packing
Only ~r x" &
Channel Integral with Double Split Flow X
Tube Sheet and
Removable Cover Floating Head
with Backing Device
Packing
T r
N Divided Flow V
T
Pull Through
Channel Integral with X Floating Head
Tube Sheet and
Process Engineering Channel

Removable Cover K
L XT
U tr
Kettle Type Reboiler
U-tube Bundle

D X Packing

X
@ProcessEng

J W
Special High Pressure Externally Sealed
Closure Cross Flow Floating Tube sheet

Fig. 6.9 TEMA-type Designation for Shell and Tube Heat Exchangers'. (Fig. No. N-l.2 of T£MA
8th Edition)
(Reproduced with the Permission of Tubular Exchanger Manufacturers Association. Inc.
USA.)
 Process Design of Heat Exchangers ' 57

where, m = Mass flow rate of vapour, kg/s

CL = Specific heat of condensate, kJ/(kg ■ 0C)
A = Latent heat of vaporization, kJ/kg
(c) For reboilers

(p = mvA x 1.05 (considering 5% heat loss) (6.9)

where, my = Vaporization rate, kg/s

A = Latent heat of vaporization, kJ/kg

Actually heat duty of the reboiler is determined based on energy balance
around distillation column.

6.3.2 Selection of Cooling Medium or Heating Medium

Selection of cooling or heating medium mainly depends on the temperature (inlet

temperature) at which cooling medium or heating medium is required. Other
factors like heat transfer coefficient provided by cooling medium or heating
medium, cost of the medium, etc. are also considered in the final selection. Table
6.5 and Table 6.6 can be used as a guideline for the selection of healing medium
and cooling medium respectively.

Table 6,5 Commonly Used Heating Fluids

Heating medium Recommended temperature range

Saturated steam 100 to 180° C

Oil (Thermic Fluid) 180 to 300° C
Dowtherm E 180 to 260° C
Dowtherm A 300 to 400° C
Molten salt 400 to 590° C
Na-K alloys 590 to 750° C
Flue gas or Hot air 750 to 1100oC
Electric heating > 1100oC

Table 6.6 Commonly Used Cooling Medium

Cooling medium Operating range Recommended to use for

Process Engineering Channel

temperature
1. Brines -68 to 50C < 80C
Examples:
Ethanol water solution -5 to 50C < 80C
Methanol water solution -33 to -10C < 80C
Ethylene glycol -34 to 50C <80C
Aqueous solution of
@ProcessEng

calcium chloride -20 to 0oC < 80C

Aqueous solution of
sodium chloride -9.4 to 50C <80C
Methylene chloride -67.7 to -37.20C <-330C
Trichloroethylene -67.7 to -37.20C <-330C
Trichlorofluoromethane -67.7 to -37.2°C <-330C
(Con id.)
 Introduction to Process Engineering and Design

Table 6.6 (Could.)

Cooling medium Operating range Recommended to use for

temperature
2. Chilled water 5 to 120C < 350C
3. Cooling water 32 to 60oC 35 to 100oC
4. Oil -1 to 3160C < 300oC
5. Air Atmospheric temperature > 60oC

6.3.2. / Heating Mediums

If temperature of heating medium is required in between 100° to 180oC, saturated

steam is used as heating medium. Saturated steam condenses in dropwise manner,
hence it provides very high heat transfer coefficient [about 6000 W/(m2 • 0
C)].
Superheated steam is not selected as heating medium for indirect (through the
wall) heat transfer because superheating zone provides very low heat transfer
coefficient.
If the temperature of heating medium required is greater than 180oC, then use
of saturated steam as a heating medium is not economical. From 180oC to 300oC,
hot oil (thermic fluid) is preferred as heating medium. Hot oil system is easily
available at comparatively low cost. Hot oil provides low heat transfer coeffi-
cient and also properties of oil are uncertain. For the precise application at large
scale Dowtherm E can be considered as a heating medium. Downtherm E is
specially processed orthodichlorobenzene. Aluminium should not be used with
Downtherm E. Downtherm A is an organic fluid of high heat stability, an eutectic
mixture containing 73.5 percent diphenyl oxide and 26.5 percent diphenyl by
mass. Both, Downtherm A and Downtherm E were developed by Dow Chemical
Company, USA. Molten salts are a molten mixtures of inorganic salts, one of
which is an eutectic consisting 40% NaNCU, 7% NaNOj and 53% KNO3. 56%
Na and 44% K (by mass) and 22% Na-78% K (by mass) are used as sodium
potassium alloys.

6.3.2.2 Cooling Mediums

In refrigeration terminology a brine is any liquid cooled by a refrigerent and

circulated as a heat transfer fluid. Operating temperature range is -680C to 50C.
Process Engineering Channel

For any fluid to be cooled below 80C (minimum possible temperature of chilled
water, 50C + minimum driving force required for heat transfer in shell and tube
heat exchanger, 30C), brines are used as cooling medium. Brine may be:
(a) An aqueous solutions of inorganic salts, e.g. sodium chloride solution, cal-
cium chloride solution, etc.
(b) Aqueous solutions of organic compounds such as alcohols or glycols, e.g.
@ProcessEng

ethanol, methanol, ethylene glycol, propylene glycol, etc

(c) Chlorinated or fluorinated hydrocarbons, ex. melhylene chloride, trichloro-
ethylene, trichlorofluoromethane, halogenated hydrocarbons as refrigerants.
etc.
Outlet temperature of chilled water from chilled water plant ranges from 5 to
15 C. While its return temperature is kept from 70C to 120C. When any fluid is to
0

be cooled below the temperature equal to design temperature of cooling water

 Process Design of Heat Exchangers

from cooling tower + minimum driving force required for heat transfer in shell
and tube heat exchanger (30C), chilled water is used as cooling medium.
Cooling water is the most widely used cooling medium at near ambinent tem-
perature.
Design temperature of cooling water from cooling tower = Wet bulb tempera-
ture + Approach to the wet bulb temperature (ranges from 4 to 60C).
Cooling water can be used as cooling medium even though inlet temperature
of hot fluid is more than 100oC. But in this case extra care must be taken as at any
time cooling water can be converted into steam. In case of exothermic reaction,
oil (thermic fluid) is used for dual purpose. Initially to achieve the reaction tem-
perature, oil is used as heating medium. Then after as the reaction proceeds, the
same oil is used as cooling medium. For this, one heater and one cooling water
cooler (or economizer) are provided in oil cycle.

Oil
Expansion
M
Tank

Cooler
-0-
fx]

Fuel Fired Boiler

or
Electric Heater
Fig. 6.10 Hot Oil (Thermic Fluid) Cycle

6.3.2.3 Air Cooling

Air cooled heat exchanger has certain advantages as well as disadvantages over
cooling water cooled heat exchanger using cooling water.
Process Engineering Channel

Advantages:
(i) Generally operating cost of Air Cooled Heat Exchanger (ACHE) is less
than the same of Water Cooled Heat Exchanger (WCHE). Operating costs
of WCHE includes cost of make-up water for the cooling tower, power
required for the cooling tower fans and for the circulating pump, cooling
tower maintenance, etc. While operating cost of ACHE includes cost of
@ProcessEng

power consumed by fan. Day by day cost of water increases and hence the
difference in operating cost between WCHE and ACHE increases.
(ii) Inlet temperature of water to cooling tower (or outlet temperature of cool-
ing water from heat exchanger circuit) should not be greater than 60oC
otherwise it creates the scale formation and also affects the material of con-
struction of cooling tower. While for air there is no limit for temperature.
(iii) Fouling or scale formation does not take place with aircooling.
 ' 60 Introduction to Process Engineering and Design

Disadvantages:
(i) Fixed cost of ACHE is higher than the same of WCHE. Heat transfer coef-
ficient of air is quiet less than heat transfer coefficient provided by cooling
water and hence heat transfer area required by ACHE is more. Also design
inlet temperature of cooling water from cooling tower is always less than
design ambient temperature. It gives lesser Mean Temperature Difference
(MTD) for ACHE compared to the same for WCHE and hence it increases
heat transfer area required for ACHE.
(ii) Minimum driving force required for heat transfer, Armin is 10° to 150C for
ACHE ad 3 to 50C for WCHE. Hence minimum temperature that can be
achieved with ACHE is ambient temperature plus 10oC, while with WCHE
it is design temperature of cooling water from cooling tower plus 30C. Hence,
if the fluid is to be cooled or condensed below 550C in a tropical location,
ACHE cannot be used.
Based on atmospheric conditions, cost of heal exchangers and cost of water,
one can find out the temperature above which ACHE becomes cheaper than
WCHE.

6.3.3 Fluid Allocation

(a) Fluid allocation in case of phase change:

Condensing or vaporizing fluid is normally taken on shell side as in the
shell liquid and vapour phases are easily separated. In case of a condenser,
if condensation is carried out in tube side, then the entire liquid condensate
forms a film on heat transfer surface which provides additional resistance
to heat transfer. In case of reboilers normally on both sides phase change
take place and hence fluid allocation depends on other factors.
(b) Fluid allocation in case of no phase change:
If there is no phase change in shell side and tube side fluid, then fluid allo-
cation depends on the following factors.
(i) Corrosion: Corrosive fluid is allocated tube side as the cheaper material
like mild steel can be used for costly shell, baffles, etc. Also, other
costlier parts like tubes and tube sheets require the use of non-corrosive
or costlier material of construction in case of corrosive fluid, whether it
Process Engineering Channel

is on tube side or in shell side. For example, in cooling of ethyliodide,

it should be taken on lube side as it requires the use of special material
(Hastelloy-B).
(ii) Fouling: In fixed tube sheet heat exchanger inside surface of tubes can
be easily cleaned and hence the fluid which has the greatest tendancy
to foul on heat transfer surface should be placed in the tubes. For
example cooling water has a tendancy to foul. Hence normally it is
@ProcessEng

passed through tubes.

(iii) Fluid Temperature: At very high temperature as well as at very low
temperature use of special alloy is required. Hence, very hot or very
cold fluid is placed on tube side to avoid the use of costlier material for
the shell. At moderate temperature, hotter fluid is belter passed through
 Process Design of Heat Exchangers

tubes. If it is placed on shell side more insulation is required not only to

reduce the heat loss but also for safety purpose.
(iv) Operating Pressure: High pressure stream should be placed on tube
side as high pressure tubes are cheaper than high pressure shell. Diam-
eter of shell is very much greater than diameter of tubes hence its thick-
ness is more sensitively changed with change in pressure as compared
to that of the tubes.
(v) Fluid Flow Rates and Viscosity: Very low value of flow rate of fluid
and high value of viscosity of fluid give low value of Reynolds number.
Fluid which provides very low value of Reynolds number should be
placed on shell side as the dependency of shell side heat transfer coef-
ficient on Reynolds number is less as compared to the same of tube
side heal transfer coefficient. Hence, for the lower value of Reynolds
number shell side heat transfer coefficient is higher than tube side heat
transfer coefficient. For example, in cooling of viscous oil, it is allo-
cated shell side as it provides poor Reynolds number.

6.3.4 Establish Energy Balance or Heat Duty Balance

and based on that Find the Mass Flow Rate of
Heating Medium or Cooling Medium Required

For example in case of condenser

0, = mX = mwChJt2 - /,) (6.10)

where, m = Mass flow rate of vapour condensed, kg/s
A = Latent heat of condensation kJ/kg

mw = Mass flow rate of cooling medium required kg/s

CLw = Specific heat of cooling medium kJ/(kg ■ 0C)
tj, tl = Outlet inlet temperatures of cooling medium, 0C

6.3.5 Mean Temperature Difference

Mean temperature difference (MTD) is calculated from equation

ATm = FlA^m (6.11)
0
where, = Logarithmic mean temperature difference, C
Process Engineering Channel

can be determined by following equation

AT2 - A'T,
(6 12)
-
In -
V A^i
@ProcessEng

where, A^ and AT^ are terminal temperature differences.

For 1-1 heat exchanger (one shell side pass and one tube side pass), F, = 1
When shell side passes and/or tube side passes are more than one, F, must be
determined.
F, =f(R, S) where R and S are temperature ratios (6.13)
 162 Introduction to Process Engineering and Design

R = (6.14)
h ~h

h fi_
S= (6.15)

where, ^ = Hot fluid inlet temperature

% = Hot fluid outlet temperature
tx = Cold fluid inlet temperature
t1 = Cold fluid outlet temperature
Graphs of F, vs S for the different values of /?, for the different cases are given in
Ref. 1. Figure 6.11 gives values of F, for even number of tube passes. If F, < 0.75,
economic design of shell and tube heat exchanger cannot be achieved. For such a
case alternate type of heat exchanger design should be considered. In the cases
where temperature cross is likely to occur, multiple shell pass heat exchanger or
more numbers of heal exchangers in series, should be considered.

Ft
OJ

0.6

0 0,1 0.2 0.3 0.4 0.5 0.6 0,7 0,8 0.9 1,0
Process Engineering Channel

Fig. 6.II Temperature Correction Factor: One Shell Pass; Even Number of Tube Passes'
(Fig. T-3.2A ofTEMA. 8th Edition)
(Reproduced with the Permission of Tubular Exchanger Manufacturers Association, Inc.
USA.)

6.3.6 Estimation of Overall Heat Transfer Coefficient

@ProcessEng

Assume the value of [/, overall heat transfer coefficient. For this, use the stand-
ard tables, in which the range of the values of U for the different cases are given.
Refer Table 6.7 for the recommended values.
 Process Design of Heat Exchangers ' 63

Table 6.7 Typical Overcell Coefficients for Shell and Tube Heat Exchangers

Shell side Tube side U, W/(m2 • 0C)

[A] Heat exchangers

1. Water Water 800-1400

2. Organic solvent Water 300-850
3. Organic solvent Brine 200-500
4. Light oil Water 350-900
5. Heavy oil Water 60-300
6. Water Brine 600-1200
7. Gas Brine 15-250
8. Gas Gas 10-50
9. Gas Water 20-300
10. Naptha Water 300-400
11. Lube oil Water 150-500
12. Gasoline Water 350-550
13. Kerosene Water 150-300
14. Water 10 to 30% 500-1250
Caustic soda solution

[B] Condensers

1. Organic vapour Water 700-1000

2. Organic vapour + Gas Water or Brine 100-300
3. Low boiling hydrocarbons Water 450-1100
Vapour mixture
4. Naptha vapour Water 300-425
5. Steam Water 2000-5000
6. Alcohol vapour Water 500-1000
7. Saturated Organic vapour Water or Brine 280-680

[C] Vaporizers/Reboilers

1. Light organics Steam 800-1200

2. Heavy organics Steam 600-900
3. Aqueous solution Steam 1000-1500
4. Chlorine Steam 700-1500
Process Engineering Channel

5. Ammonia Steam 700-1500

6. Water Steam 1250-2000
7. Refrigerants Water 425-850

Find out heat transfer area based on this selected or assumed value of U.

0/
A = (6.16)
@ProcessEng

U x A'4,

For the 1st trial calculation, this A is the heat transfer area provided or actual heat
transfer area of heat exchanger.
A=Ap[0 = Nt7id0L (6.17)
 Introduction to Process Engineering and Design

where, d0 = Outside diameter of tube, m

L = Tube length, m
Nt = Total number of tubes
Values of d0 and L are decided by designer and from Eq. (6.17), value of Nt is
determined. Then for the first trial, number of tube side passes and shell side
passes are decided. Tube arrangement and type of heat exchanger are also de-
cided.

6.3.7 Finding Shell Diameter

Based on all these informations find the inside diameter of shell. Select the type
of baffle. First choice is 25% cut segmental baffle. Fix the value of baffle spac-
ing. If there is cooling or heating on shell side then for the first trial baffle spac-
ing Bs could be 0.3 to 0.5 times shell ID and if there is condensation or boiling on
shell side, Bs could be equal to shell ID for the 1st trial.

6.3.8 Calculations of Tube Side Heat Transfer Coefficient

(a) For heating or cooling on tube side (no phase change), tube side heat transfer
coefficient is determined by Sieder-Tate equation. If Re is less than 2000.

,0.33 0.14
h di d,
Nu= -^ = 1.86 Re - Pr- JL (6.18)
k pw
f

In this equation
If Nu <3.5 then Nu is taken 3.5.
If Re > 4000, tube side heat transfer coefficient is determined by Dittus-Bolter
equation;

/ \0.14
hid; 0.8 d. 0.33 _P_
Nu = = C Re™ Pr (6.19)
Pw

where, Nu = Nusselt number =

Process Engineering Channel

k
f

dj u, p dj Gt
Re = Reynolds number =
P P

CPP
@ProcessEng

Pr = Prandtl number -

/?, = Tube side heat transfer coefficient, W/(m""- 0C)

dj = Tube ID, m
 Process Design of Heat Exchangers

L = Length of tube, m
k = Thermal conductivity of fluid, W/(m • 0C)
Cp = Specific heat of fluid, kJ/(kg ■ 0C)
'f
jj. = Viscosity of fluid at the bulk fluid temperature, (N • s)/m
jUw = Viscosity of fluid at tube wall temperature, (N • s)/m2
C = Constant
C = 0.021 for gases
= 0.023 for non-viscous liquid = 0.027 for viscous liquid
Gr = Tubeside mass velocity, kg/(m2 • s)
^ m
(j
i=
a,

N
t ..n ,2
where, a, = Tube side flow area = —— x —d~ (6.20)
i\p i

m = Tube side mass flow rate of fluid, kg/s

N, = Number of tubes
Np = Number of lube side passes
u, = Tube side fluid velocity = G/p, m/s
p = Density of fluid, kg/nr
To calculate tube side heat transfer coefficient, first calculate tube side flow
area (a,) then tube side mass velocity (G,), then tube side Reynolds number (Re)
and tube side Prandtl number (Pr), then depending on the value of Re, use
Eq. 6.18 or Eq. 6.19 to calculate /?,.
For the transition region or for 2000 < Re < 4000, no reliable equation is
available. Hence, for this region h-, is found by using both Eqs (6.18) and (6.19)
and the lesser of two values is considered.
Tube side heat transfer coefficient h, can be calculated from the value of "heat
transfer factor, J),", for the entire range of Reynolds number (from Re = 10 to
106). Equation relating /z, and Jh is

\0.14
Process Engineering Channel

P
Nt = hid]r = Jl.RePr'>* (6.21)
k vAL v y
Graph of Jh versus Re is given in Fig. 6.12 for the different values of L/dp
(b) For condensation inside the tubes.
Condensation coefficient depends on the position of condenser. For condensa-
tion, shell side condensation with horizontal position is the best which gives the
@ProcessEng

maximum value of the coefficient. But if condensation is carried out in tube side
then for horizontal position /z, is calculated by following two equations and higher
of the two values is considered.

Pl (Pz. — PL ) 8 V
(i) hci = 0.76 kL (6.22)
Pth J
 Introduction to Process Engineering and Design

v
id
<u
>
-52
UJ

c
o
5 -
OS l2
«a V—<
o lO oi
c -c
UJ £
3
• ■ z
O
175 <D
i 2 ■O
o X O)
c 0) u
>> T3 3
o "O
Z o
i-
(U •CL
-a <U
(5 a:
o
(N
-O
M

a
Process Engineering Channel
@ProcessEng

o- ocr- >o m rs o* ^cr- *c «7i 1-5 r-i

h h
'If 'JOJDB j J3JSUEJX IB3H
 Process Design of Heat Exchangers

This equation is Nusselt equation, valid for stratified flow,

where, hci = Condensation coefficient, W/(nr • 0C)
kL = Thermal conductivity of liquid condensate, W/(m • 0C)
pL = Density of liquid condensate, kg/nr
pv = Density of vapour, kg/m3
g = Acceleration of gravity = 9.81 m/s2
P/ = Viscosity of liquid condensate, (N ■ s)/m or kg/(m • s)
Zh = Horizontal tube loading or flow of condensate per unit length of
tube, kg/(m ■ s)
All liquid condensate properties kL, pL and pL must be determined at mean tem-
perature of condensate film.

Wr
th =
LxN,

where, L = Tube length, m

Wc = Total condensate flow, kg/s
Nj = Total number of tubes

' + V PiJPv
(ii) hci = hi' (6.23)
2

where, hf = 0.021 Re™ Pr0 43

d, j
This equation is known as Boyko-Kruzhilin equation, valid for annular flow.

4r
' /;
Rer = Reynolds number for the condensate film = (6.24)
Pl

CpL pL
Prc = Prandtl number of liquid condensate = (6.25)

where CpL, pL and icLare properties of liquid condensate which must be deter-
mined at the mean temperature of condensate film.
Process Engineering Channel

/ x \l/3
Pl(PL - Pv)8
For vertical position, hcj = 0.926 kL (6.26)

Wc . . 4t
where, Tv = , Wc = Mass flow rate of liquid condensate kg/s, Rec =
c
N.nd, ' Pl
@ProcessEng

This equation is also called Nusselt equation, valid for Rec < 2000. For Rec >
2000, use Boyko-Kruzhilin equation, i.e. Eq. (6.23).

6.3.9 Calculation of Tube Side Pressure Drop

(a) If their is no phase change in tube side fluid, then tube side pressure drop can
be calculated by following equation.
 Introduction to Process Engineering and Design

\—m
pwr
A/;, = N 87, + 2.5 (6.27)
w y

m = 0.25 for /^<? < 2100 and m = 0.14 for Re > 2100
,2
where, Ap, = Tube side friction pressure drop, N/m or Pa
Np = Number of tube side passes
Jf= Tube side friction factor can be obtained from Fig. (6.13)
p = Density of tube side fluid, kg/nr
u, = Tube side fluid velocity, m/s
Ap, calculated by this equation is actually permanent pressure loss. Calculated
pressure drop (loss) should be less than maximum allowable pressure drop. In
some applications, maximum allowable pressure drop is decided by process con-
ditions. While in other applications, maximum allowable pressure drop is actu-
ally optimum pressure drop (loss). Heat exchanger design means the balance
between two opposite factors, heat transfer coefficients related to fixed cost and
pressure drop related to operating cost. Increase in heat transfer coefficient by
modifying the heat exchanger design also increases pressure drop. Hence, ide-
ally actual pressure drop should be equal to optimum pressure drop which gives
the total cost of heat exchanger (i.e. fixed cost + operating cost) minimum. As a
general guideline (Table 6.8) can be used to decide the value of maximum or
optimum pressure drop. As per Kern, optimum pressure drop for gases is 2 psi
(13.8 kPa) and for liquids it is 10 psi (69 kPa) (Ref. 5).
(b) If condensation takes place inside the tube then it is difficult to predict the
pressure drop as vapour mass velocity is changing throughout the condenser. A
common practice is to calculate A/7,'by Eq. (6.27) for inlet vapour flow rate and
conditions, and multiply it by factor 0.5.
Ap, = 0.5 Ap', (6.28)

6.3.10 Calculation of Shell Side Heat Transfer Coefficient

(A) For heating or cooling on shell side or for no phase change on shell side, heat
transfer coefficient h0 can be calculated by following procedure.
(a) Calculate shell side flow area by following equation
Process Engineering Channel

{Pt-d^DsBs
As - (6.29)
P,
where, As = Shell side flow area, m2
p, = Tube pitch, m
d0 = Outside diameter of tube, m
@ProcessEng

Bs = Baffle spacing, m
Ds = Shell inside diameter, m
(b) Calculate shell side mass velocity Gs and linear velocity {us)

Wc
Gs = and us = (6.30)
Ac Ps
 Process Design of Heat Exchangers 169

T I I—I i r -i
- t- H I
11 -|- r
H H -I- f-
+ 4 H — J- H 4 - U -I I L
X 4 4-U _l I
r • rn
4 4 4-U. -J - U -4- -J 4 4--
44 J_l_ J J _ _L 44—I—I I I L J J_l_ L
I I
— h- H 4 4 -4-1- -4- -I 4 4-1-

TT 11 I "T "I-l-rn in-i

ii i i

4-1-1-4 --I- 4 4 4-1-4 1- 4 4-1- r

444-U4 -I--I 4 4 -I- i- -
1i J _L J J L J 4 J_ L J J L J J-l-L
T Til I rn 44 1
1 4 J _ L J __L _L 4 J J _l_ L _
liJ_LJ J L i J J_ LJ J L JJJ_L_
4 4 4—1—4 4I 4I -J—
I J- -I 4- 4 4 - - i-
I
T 4 4-T 4 —r -r4 4I 4 -|- r
m <D
i ii i i O >
01
——t (-4—1 i=! -£2
+ 44—1-4 4 4 4-h uj
4 4 4—1—4 4 U -I 4I 4 4 — — t" —
4 4- - 1- c
liJ_LJ
I I I J L JJJ_LJ J L JI JI II L o c
T44-r4 4 4 -i-r 4 4 4" - •—
CJ
i-i J_l_ J J _l o
f J J L JJJ_LJ J L -D
'J JI JI JI _ II II 1 "U E
4 4 4 — 1—4 -U4 4 4-1 z
"M Co
2 QJ QJ
T 4 4-r 4 4 4 4-r 4 4I o -Q -C
,3
4)
U4—I I—1-4 -1-4 a: ro i
+ 4 4—1—4 4 I- 4-- —; Ts
14 4-1-4 4 - -U 444^L4 4- _ L 4-1- L- O
^ o QJ
+44-r4 -1-4 4 44-" M -o
1-1
I I J_L
I J J__L JJJ_LJ J--L J J_ -L_ -'--1 \L 2
II I •Q-
QJ
II I cc
1 J J _ L_ J _L 4 J J- -

+44-^4 -1-4 4 4 -I- r -

1 l I l

144-1-4-4 1- ■yq 4-1- 4- 4 1-

Process Engineering Channel

1JJ_I
I I I I II II LI tfJJ_LJ_J__L
I I I I I I I J_ J J _ _ L _ J__L
m-n-T-r
+ 14-1-4-4 1- ni-n-T-r II -1- -
4 4 4-1-4-4 I- 4
II I I I I I
I I I I I I
mn
ii J_I_ j_ j_ j_ _1 I I L J- J J _l_ L
I
+44-H4- -1- -1-4-4- 4 4 -I- f-
I
@ProcessEng

I I I
cocr- o wj 4 Ovccr- O */-i 4- ro a> cct-- >c m 4-

Jf 'jopej uoijouj
 170 Introduction to Process Engineering and Design

where, Gs = Shell side mass velocity, kg/(m2 • s)

ms = Shell side mass flow rate of fluid, kg/s

ps = Density of shell side fluid, kg/m3
(c) Calculate the shell side equivalent diameter (de) for square pitch arrange-
ment.

4 x cross sectional area

de =
wetted perimeter

TT
4x ^-^2
4
TTr/,,

1.27
(P,2 - 0.785d;) (6.31)
d,.
For triangular pitch arrangement,

4xf|p,x^sin60-|^

(nd0l2)

de=^-(Pr-0.901 dl) (6.32)

do
(d) Calculate shell side Reynolds numbers

deGs
Re = (6.33)

where, p = Viscosity of shell side fluid at average temperature, kg/(m • s)

Also calculate shell side Prandtl number

CPP
Pr = (6.34)

Cp, p and k are the properties of shell side fluid at average temperature,
(e) Calculate the shell side heat transfer coefficient by following correlation
Process Engineering Channel

(Ref. 5).

,0.14
h,. d„
Nu = () 55
= 0.36 Re - Pr {U3 JL (6.35)
AC

This correlation is valid for the range of Reynolds number from 2000 to
1000 000. Shell side heat transfer, coefficient can be found out from "shell
@ProcessEng

side heat transfer factor, Jh".

/ \0.14
Nu = = Jh -Re ■ Pr 0 33 JL (6.36)
Pw
Graph of A versus Re given in Fig. 6.14.
 Process Design of Heat Exchangers

o- DC r- -c "/"> T c- cc r- >o in -T m csocr- o «n "T

i I I I
frT-r-r-r --r
t- rrn -1- -
s □ - -i- i—• I— L_ J—I I I 1
i i i " i §u -o --I-'
rt--t-1-T-T r-
g 2 t in -r I I I r-i 1
t--\ 1
-I- f- -1
TfTT'T |< Tlj
_L I ■■ 1- l >_L J_ -LI J L
i i i E i i i i i
i i i
-+- x , -f H -I- h H -I
I
II II I I I
I I I
I I I I II ■I
4 4—— I 1 -I
4 4 _l_ L J
l Li Ji _ Ll _!I i! _ "JJ_LJ_
-Ti -ii -i— r —i
_ L1 J L _
i i r-r- I !
_L
I I JI _ Il 1I II _ 1 J L J_ _ LI J I L _
i LI Ji _ LI _ II II _ 4I JI _<I L < i Ji L _
-LI
i i i I I i ii i
— I—i
i
i i i■ ill ill
i
ii i
i
i
i ti ni-i—i
i i ir — ir
rTTT-rT-n—r I I I rr
rrn
+ + H-I l-^ H
i-IJ-l I I 1_ -ULLJ_L_ . L_1 I
I I -rt-
-l- I I I I I t-t-i-r-i- 1--1 1
- h -t - ■t -t -i- - -1-
I —
-Ll-L-1 L_ ±1- i in
•n ^
- f- 4 - 4 4 —I — - H - v _ I- 4 4

_L4 4 J _ _ L _J I _ L 4 _1
_ L4 4 4 _ _ L _) I _L4
Li LJ
-n t T - - r -i- r n -1
L" Li
_ L i L-1 i' L _ L J L _! I
-4H
Process Engineering Channel

III
44 — H 4 HI 4-1 1
I— I— L 4 _ I I I 44 _J L L L 4 L -I I
I I I I I - -1 -1-4- 4-1
4H I f -4 4-
r
-44 4 4-1-4-1- —4 — -
@ProcessEng

o^oor^ so -4 C 00 4- so -4 osoor-' so H-

'If 'JOPBJ J3JSUBJX 1B3H

 Introduction to Process Engineering and Design

(B) If condensation takes place on shell side then its coefficient depends on the
position of condenser.
Shell side condensation coefficient for horizontal position can be determined
by following modified Nusselt equation.

1/3
Pz,(Pz.-A.)g -1/6
hco - 0-95 kL N (6.37)
Pl?"/,
/■)
where, hco = Shell side condensation coefficient, W/(m • 0C)
3
kL = Thermal conductivity of liquid condensate, W/(m C)
3
p, = Density of liquid condensate, kg/m
pv = Vapour density, kg/m3
g = Acceleration of gravity = 9.81 m/s2
pL = Viscosity of liquid condensate, N • s/m2
Th = Horizontal tube loading or flow of condensate per unit lengh of
tube

LN,
where, Wc = Total condensate flow, kg/s
L = Tube length, m
Nj = Number of tubes
A,. = Average number of tubes in vertical tube row

Nr=\N; (6.38)

N ' = Number of tubes in central row

a,
n: = (6.39)
p.
Dh = Tube bundle diameter, m
P, = Tube pitch, m
For condensation outside the vertical tube bundle, shell side condensation coeffi-
cient is given by Nusselt equation.
Process Engineering Channel

>1/3
Pl(PL -Pv)g (6.26a)
^co ~ 0-926 kL

c
where, (6.26b)
Nt 7id,.
@ProcessEng

6.3.1 I Calculation of Shell Side Pressure Drop

(a) For no phase change on shell side or for heating or cooling on shell side, shell
side pressure drop Aps can be calculated by following equation.
\-0.14
L Ps"s P
Ap= 87, (6.40)
V ) Bs y 2 \p.w y
 Process Design of Heat Exchangers

where, Aps = Shell side pressure drop, N/m2 or Pa

Ds = Shell inside diameter, m
de = Shell side equivalent diameter, m
L = Tube length, m
Bs = Baffle spacing, m
ps = Density of shell fluid kg/m3
us = Shell side linear velocity, m/s
fi = Viscosity of fluid at the bulk fluid temperature. (N ■ s)/m
pw = Viscosity of fluid at tube wall temperature, (N ■ s)/m
Jf = Shell side friction factor for the different values of % baffle cut
of segmental baffle and for the different values of Re, it can be
obtained from Fig. (6.15).
Shell side pressure drop Aps should be less than maximum allowable pressure
drop. Maximum allowable pressure drop for shell side is also decided either based
on process requirement or based on economic considerations.
Table 6.8 can be used to judge optimum pressure drop.

Table 6.8 Optimum Pressure Drop (Maximum Allowable Pressure Drop) based on Economic
Considerations (Ref. 4)

Fluid Optimum, Ap, or Aps, kPa

Liquids of pL < 1 cP 35
Liquids of p, = 1 to 10 cP 50 to 70
Gas or vapour at 1 to 2 atm 13.8
Gas or vapour at high vacuum 0.4 to 0.8 (3 to 6 torr)
(up to 60 torr absolute pressure)
Gas or vapour at high pressure > 10 atm 0.1 times operating pressure

(b) In case of shell side condensation no reliable correlation is available for

predicting Aps. Hence, Aps can be approximately calculated by following equa-
tion.

Aps = 0.5 Ap ' (6.41)

where Ap/ = shell side pressure drop calculated by Eq. (6.40) based on inlet
Process Engineering Channel

vapour flow rate and inlet conditions.

This also should be less than maximum allowable pressure drop.

6.3.12 Calculation of the Overall Heat Transfer

Coefficients by Following Equation
@ProcessEng

Uo (6 42)
~ 1 , 1 , | d0 ^ | ^ x 1 "
2k d d h
ho hot, w i Ki i i

where, U0 = Overall heat transfer coefficient based on outside area of tubes,

W/(m2 ■ 0C)
 174 Introduction to Process Engineering and Design

- *— h — + 1 HH-
UI--1-I — I t 4-
-I 1
-l 1 -1-4- --hH
-l-l-
hH
- U -I
-I- 4- -4. -I- - -4-4- - 4- -4
I I I I H H - -I
-1-4-4 -H -

-4 ■ 4 -I 1 4-1- — 4- -

rr rrr-i-r
4-i — i--1-- 1 "1 -
-r- t4 1
nn
r rTT-r-r-r
4 1-4-I - 4 -1-- 4 -i— — i — -in -in -
L L 1 J _ L _I 1 jJ
r r 4 -r -|—i -i -i
1114 r i nn
1-L4--I-L-I 4 -I 1 —i J

rrn rrr t r i nn r i

r > -i n
rm-r-r-T rrn-r-i n-i
rrjn-r-r-T ii i r r i
U 4 -I- -I | 1 -I -4
i i i i r -r r r -i
rrrT rr i
U 4 -I- -4=4-
II I I I I □^
rm-r-i rr-n -• ""
ii i i i i i = -a
ii i i i i i i = <1
rm-r-r-T rt i—i
rm-r-r-i i i
iiit ri r i i i
rm-r-r-T
rrT~i~r~r"T rr r t t -1 1
I— I— 4-4-1 1 1 1
iriii
LiJ II I I I I I I
ii ii ii ii
-4-1 4 (- -I 4-
II I I
II I I

LL1J-L-L
LL1 J_L_l_
LL1J_L_L. ULLL1
I- LU 44
I-1-
J J_ -I
JJ-J_
_L Jl
J- _ 1 I 4J _ -I-
L
J..U
LI LIJ
l l l _ Il _ IL LJ
Process Engineering Channel

rr r -11- -r-i1
LLlJ_L_L
II I I I I J J- _ 1 J__l_
LLJ.J_J L_ l_ L 44- — I 1 4 1_
rrtt m r -i
4 -4 U4
III
lit
III
I'll
@ProcessEng

'/• 'JOJOB j UOipiJj

 Process Design of Heat Exchangers

h0 = Shell side heat transfer coefficient, W/(m2 • 0C)

d0 - OD of tube, m
^, = 10 of tube, m
kw = Thermal conductivity of tube wall material, W/(m ■ 0C)
hjd = Fouling coefficient for tube side fluid, W/(m2 • 0C)
hod = Fouling coefficient for shell side fluid, W/(m2 ■ 0C)
For the various types of fluids, recommended fouling coefficient are given in
Table 6.9.

Table 6.9 Recommended Fouling Coefficients (Ref. 4. 6 & 7j

Fluid Fouling Coefficient Fluid Fouling Coefficit

2
W/(m • "C) W/(m2 • "C)
Cooling water 3000-6000 Aqueous Organic Solution 5000
Steam 4000-10 000 Vegetable oils 3000
Steam condensate 1500-5000 Caustic Solutions 5000
Brine 3000-5000 Gasoline 5000
Air 5000-10 000 Kerosene 3000-5000
Organic vapours 10 000 Light gas oil 3000-5000
Organic liquids 5000 Heavy gas oil 2000-3000
Heavy hydrocarbons 2000 Napthas 5000
Aqueous salt solutions 3000-5000 Coal flue gas 1000
Light Hydrocarbon 5000
Heavy Hydrocarbon 3000

6.3.13 Calculating the Heat Transfer Area Required

A = — (6.43)
U0A%n
Also calculate actual heat transfer area A0.
A0 = N,Kd0L

4
{1.1 to 1.2}
4eq
Process Engineering Channel

An. An.
' ~ {0.8 to 1}, ——— e {0.8 to 1}
A
P, max fys max

Thus an optimum design of shell and tube heat exchanger can be obtained.

Example 6.1
@ProcessEng

A lube-oil cooler for 2 MW steam turbine is to be designed for following operating

conditions. Lube-oil, conforming to ISO VG-46 grade, flows at the rate of 450 L/min
and is to be cooled from 650C to 450C with cooling water.
Kinematic viscosity of lube oil = 45.5 cSt at 40oC.
Density of lube oil = 869 kg/m3
Specific heat of lube oil = 2.1413 kJ/(kg • 0C)
Thermal conductivity of lube oil at 550C = 0.13 W/ (m • 0C)
 Introduction to Process Engineering and Design

Viscosity of lube oil at 550C = 15 cP

Cooling water inlet temperature = 35 0C
Cooling water outlet temperature = 390C
Solution:
Heat duty, 0, = m0 CLo At
Volumetric flow rate of oil = 450 L/min = 450 x 60 x 10~3 m3/h = 27 m3/h
m = 21 x 869 = 23 463 kg/h
0, = 23 463 kg/h x 2.1413(65 - 45) LMTD
0, = 1004 826 kJ/h = 279.118 kW 650C
Heat balance

<t>,= >KCLw At
279.118= mw x 4.1868(39 - 35) 45 C
390C < 35 C
mw = 16.667 kg/s (= 60 m Vh)
A7[ = 65 - 39 = 260C
Fig. 6.16
A95 = 45 - 35 = 10oC

AT, - AT2 26-10

A^ = = 16.7450C (6.12)
^26]
In In
AT, v 10.

For the first trial calculations, let the number of tube side passes Np = A
Allocating lube oil on tube side and cooling water on shell side.

%-'h h ~l\
R = S=
h ~t\ %-h
"Tj- = 65° C, ^ = 45° C, /, = 35° C, t2 = 39° C

65-45 39-35
R = = 5, 5= = 0.1333
39-35 65 - 35
From Fig. 6.11, Ft = 0.95
Mean temperature difference. Act = F, Al{n
Arm = 0.95 x 16.745 = 15.908oC
Assume overall heat transfer coefficient U0 = 400 W/(nr- C). (Ref.: Table 6.7)
Process Engineering Channel

Provisional heat transfer area for the first trial calculation.

279.118 xlO3
A =
Vo AT„, 400x15.908
A = 43.8644 m2 = N,kc10L
dn = 5/8 in. = 15.875 mm, L = 6 ft = 1.8288 m
@ProcessEng

43.8644
N, = = 480.93 s 480
' TTX (0.015 875 x1.8288)
Select BEM type heat exchanger with tube pitch Pr = 1.25 d0 = 19.8437 mm and triangu-
lar pitch arrangement.
l/M,
Tube bundle diameter Dh = d0 (6.1)
k.
 Process Design of Heat Exchangers

From Table 6.2 for Np = 4, k, = 0.175, n, = 2.285

\ 1/2.285
D/, = 15.8751 1 = 507.5 mm
0.175
Let clearance between shell ID and Dh = 12.5 mm = 520 mm
Evaluation of /i,-:
Tube side flow area:

480 k ,2
a= x—df (6.20)
4 4'
di = 13.3858 mm (for 18 BWG tube)

a, = - (0.013 3858)2 = 0.016 887 m2

r 4 4

• • 111
Tube side mass velocity C, = —
a,

1
{ 23 463 x
G. = = 390.57 kg/(mz • s)
5
' 0.016687

Viscosity of oil:
li = 15 cP = 15 xlO-3 kg/(m ■ s)

d:G. 0.013 3858x390.57

Re = = = 348.54
R 15 x 10

To increase the Reynold number, let the number of tube side passes Np = 8
K] = 0.0365,771 = 2.675 from Table 6.2

480 2.615
Db = 15.875] = 550 mm
V 0.0365
Shell ID =0,,+ 12 = 562 mm
Evaluation of hf.

a, = -(0.013 3858)2 = 8.4436 x lO"3 m2

Process Engineering Channel

8 4

G. = 390.57 x - = 781.14 kg/(m2 ■ s)

4

G, 781.14 no .
u, = — = = 0.9 m/s
p 869
@ProcessEng

Res = 348.54 x 2 = 697

C,,!* 2.1413x15xlO-3 xlO3

Pr =
K 0.13
= 247
 Introduction to Process Engineering and Design

Using Sieder-Tate equation (Ret < 2000)

/ \0.14
h, d: R
Nu = = I MiRe ■ Pr - dJL)0.33 (6.18)
\r~w y

>0,33
0.0133858
= 1.86 697 x 247 x X 1
1.8288
= 19.618 >3.5

k 19.618x0.13
h: = 19.62 x — = = 190.526 W/(m2 ■ 0C) (too low)
di 0.013 3858

To improve oil side heat transfer coefficient, allocate lube oil on shell side and water on
tube side. Increase the tube length from 6 ft to 10 ft for the same value of heat transfer
area provided. It will decrease the shell side flow area and will improve the shell side
heat transfer coefficient
L = 10x0.3048 = 3.048 m
Apro = 43.8644 m2 = Ntnd0L = Nlx nx 0.015 875 x 3.048
N, = 288.56 s 288
Let number of tube side passes Np = 4
k, = 0.175, n, = 2.285 (Ref.; Table 6.2)

2 8 8 ) 2.285
ZX
-7. = 15.875 175j
= 406 mm

Shell ID, D,- = 406 + 12 = 418 mm

Evaluation of /i(:

a, = —x-(0.013 3858)2 = 0.01 m2

4 4

Tube side mass velocity, G, = 1

^ ^ = '666.7 kg/(m2 ■ s)

Density of water at 340C, p = 993.328 kg/m3

(Table 3.28 of Ref. 2)

G, 1666.7
Process Engineering Channel

u, = = 1.678 m/s
p 993.328

d^
Re =
R
Viscosity of water at 370C, p = 0.73 cP = 0.73 x 10 3
kg/(m • s)
@ProcessEng

0.013 3858x1666.7
Re = = 30 561.8 >4000
■v-3
0.73 x 10"

Thermal conductivity of water at 370C, k = 0.628 W/(m- 0C)

CPR
Prandtl number of water, Pr =
K
 Process Design of Heat Exchangers

4.1868 x 0.73 xl (T3 xl03

Pr = = 4.867
0.628
Using Dittus-Bolter equation

k: d, / \0.I4
08 033 P
Nu = = 0.023 Re Pi (6.19)
kf Pw

Q 628
h: = 0.023 x ' x (30 561.8)a8 X4.8670-33
0.013 3858
= 7046.6 W/(m2 ■ 0C)
Evaluation of oil side heat transfer coefficient {hn):
Shell side flow area

iP,-d0)
x Ds x Bs (6.29)
P,

PJd0 = 1.25, D9 = 418 mm, Bs = ^ = = 83.6 mm

1 -25 d0 - d0
A„ = x 0.418 x 0.0836 = 6.989 x K)"3 m2
(\.25d0)

m
Shell side mass velocity, Gs = (6.30)
a7

23 463 x
3600
G = = 932.537 kg/m2 • s
,-3
6.989x10

G
s 932.537 . n_, .
= = = 1.073 m/s
p 869
Shell side equivalent diameter for triangular pitch

de =^-(P;--0.901 d3) (6.32)

Process Engineering Channel

d,.

1.1
d = [19.8437 - 0.907 x (15.875)2]
15.875
= 11.4465 m

deGs
Shell side Reynolds number Re =
@ProcessEng

0.0114465x932.537
Re = =711.62
15x10 -3
 180 Introduction to Process Engineering and Design

Cpli 2.I4I3x (15 x ID-3) x 103

Pr =
k 0.13
= 247
Re =1\\ .62 =>,//( = 2 x IO"2 (From Fig. 6.14 for 25% baffle cut)

N.. = = Jh Re Prm (636)

cf

0.13
h=2x lO"2x x 711.62 x (247)l/3 x 1
0.0114465

= 1014.18 W/(m2- 0C)

Overall heat transfer coefficient

r i \
do_
d0 In
V Cl:' / d
o \ d
o 1
—+ —+ + + —x — (6.42)
U, h
o Kd 2 kw d
i Ki d
i h
i

From Table 6.9

hod = 3000 W/(m2 • 0C), hjd = 5000 W/(m2 ■ 0C)

/
15.875 "l
0.015 875 In
13.3858 7 | 15.875 1
+ + X
Un 1014.18 3000 2x50 13.3858 5000

15.875 I
+ x
13.3858 7046.6
0
Thermal conductivity of tube material kw = 50 W/(m • C)
Tube material: steel or cupronickel)
U0 = 570.8 W/(m2 • 0C)

Heat transfer area required, Ar = (6.43)

U0 ATm
Process Engineering Channel

279.118 xlO3
= 30.739 m2
570.8x15.908

Excess heat transfer area = -I x 100

@ProcessEng

= Kq8^4-1) X 100 = 42.7 % (sufficiently high)

 Process Design of Heat Exchangers

Shell side Pressure Drop:

/" \ / \ -0.14
(Ds' L Ps US P
Aps = 87, (6.40)
[de . \ B,s / 2 .PW ,

Ds = 0.418 m, de = 0.011 4465 m, L = 3.048 m

Bs = 0.0836 m, us = 1.073 m/s, ps = 869 kg/m3
Jr = shell side friction factor
For Res = 711.62, Jf= 7.7 x lO"2 (From Fig. 6.15)

N
0.418 r 3.048 "l
Aps = 8 x 7.7 x lO"2 x
(0.011 4465 y 10.0836 J

= 410 281.7 Pa = 410.282 kPa (too high)

To decrease the shell side pressure drop, baffles spacing can be increased from 83.6 mm
to 160 mm.
Revised value of Bs = 160 mm = 0.16 m

Shell side flow area, As = 6.989 x lO""3 x 0 16

= 0.013 376 m2
0.0836

6.989x10 -3
Shell side mass velocity. Gs = 932.537 x = 487.25 kg/(m ■ s)
0.013 376

G
s 487.25
u, = = 0.56 m/s
Ps 869

0.0114465x487.25
Re = = 371.82
-3
15x10

hsde / \0.14
P
Nu = = Jh Re Pr,1/3 (6.36)
\Pw /

for ,-2 (from Fig. 6.14)

Re = 371.82 =^ J,, = 2.7 x lO"'
Process Engineering Channel

Nu = = 2.7 x lO"2 x 371.82 x(247),/3 = 62.989

0.13
/ir = 62.989 x = 715.37 W/(m2- 0C)
0.0114465
@ProcessEng

1 1
-r
U0 570.8 1014.18 715.37

U =462.15 W/(m2 • 0C)

 Introduction to Process Engineering and Design

<t>, 279.118x10'
A,= = 37.96 m2
U0ATm 462.15x15.908

43.8644
Excess heat transfer area = -1 x 100 = 15.55% (adequate)
37.96
Revised Shell side Pressure Drop:
For Ds = 0.418 m, Bs = 0.16 m, ^ = 0.011 4465 m, L = 3.048 m, us = 0.56 m/s,
pv = 869 kg/m3

Ps^s r p \
Aps = 87, {L (6.40)
U Bs J 2

For Re = 371.82, Jf= 9.26 x 102 (From Fig. 6.15)

0.418 3.048 "j 869x0.56 x

Aps = 8 x 9.26 x 10,-2
X
0.0114465 0.16

Aps = 70 220.7 Pa s 70.22 kPa (acceptable)

Tube side Pressure Drop:
/ / \ / \ —m
L p pi'i
+ 2.5 X
-r
00
&p,=K (6.27)
d
v i) . Pw ) / y
Np = 4, L = 3.048 m, 7, = 0.013 3858 m, u, = 1.678 m/s
p = 993.328 kg/m3, plf^ = I
Re, = 30 561.8 Jf= 3.6 x lO"3 (From Fig. 6.13)

-3 3.048 993.328 x 1.678

Ap,= A 8 x 3.6 x 10 x xl+ 2.5 x
\ v 0.013 3858

Ap, = 50 668 Pa = 50.668 kPa

Comments: In this case viscosity of lube oil is very high, hence it gives very poor
Reynolds number. Fluid, which provides poor Reynolds number must be allocated
shell side to get the higher heat transfer coefficient. Flere also, by changing the alloca-
tion of lube oil from tube side to shell side, lube oil side coefficient increased consid-
Process Engineering Channel

erably. In any (without phase change) shell and tube heat exchanger for the fixed value
of heat transfer area, increase in tube length (correspondingly decrease in number of
tubes and shell inside diameter) increases the overall heat transfer coefficient but at the
expense of pressure drop or in other words increase in tube length for the fixed value
of heat transfer area decreases the fixed cost of heat exchanger but increases its operat-
ing cost.
@ProcessEng

6.4 CRITERIA OF SELECTION BETWEEN HORIZONTAL

CONDENSER AND VERTICAL CONDENSER

(i) For only filmwise condensation, horizontal position gives higher

condensation coefficient than vertical position. In filmwise condensation,
thickness of condensate film over heat transfer surface decides the value of
 Process Design of Heat Exchangers

condensation coefficient. With horizontal position and shellside

condensation, the condensate travels less distance over heat transfer surface
before falling down by gravity compared to vertical position. With vertical
position condensate travels over the entire tube length before falling down
by gravity. Hence, average condensate film thickness obtained with
horizontal position is less than the same with vertical position and hence it
provides higher condensation coefficient.
(ii) In case of condensation with subcooling in a shell and tube heat exchanger,
condensation coefficient is higher with horizontal position while subcooling
coefficient is higher with vertical postion. In case of subcooling with hori-
zontal position, small fraction of gravitational force is acting on the pool of
condensate and hence condensate is flowing with almost no turbulence.
Hence, subcooling with horizontal position is natural convection heat trans-
fer. While in subcooling with vertical postion, entire gravitational force is
acting on pool of condensate. Hence, it creates turbulence in pool of con-
densate and provides higher subcooling coefficient. Subcooling with verti-
cal position can be considered as forced convection heat transfer.
Therefore, in the case of condensation with subcooling, shell and tube
heat exchanger is designed for both positions (horizontal and vertical) and
the position that gives higher value of overall coefficient is selected.
(iii) In case of condensation with non-condensables, selection of position de-
pends on the % of non-condensables present in inlet vapours for which
guidelines are given by Frank5.
(a) If non-condensables are < 0.5 % (by mass), then the presence of non-
condensables is ignored in design calculations. Heat exchanger is de-
signed as a total condenser. For this case, horizontal position should be
selected as it provides the higher condensation coefficient.
(b) If non condensables are > 70% (by mass), then for the entire flow rate,
without phase change correlation is applied to calculate the heat trans-
fer coefficient. However, in calculation of heat duty (0,), condensation
is considered. For this case selection of the position does not depend
on heat transfer coefficient, as without phase change coefficient does
not depend on position of heat exchanger so in this case position is
decided by other factors like available area or available height.
(c) Between 0.5 to 70% non-condensables, heat transfer coefficient is de-
Process Engineering Channel

termined by considering both condensation as well as cooling of non-

condensables and vapours. For this case horizontal position should be
selected as it gives higher condensation coefficient, if condesation with
cooling is carried out on shell side. If the same is carried out on tube
side, then vertical position is better.

Example 6.2
@ProcessEng

10 900 kg/h of nearly pure saturated methyl ethyl ketone vapour at 13.73 kPa g is to be
condensed and cooled to 60oC by cooling water which is available in plant at 320C.
Consider pressure drops of 13.7 kPa for vapour and 68.7 kPa for the water as permissi-
ble. Design the suitable shell and tube heat exchanger for the heat duty.
Solution:
Heat duty calculations
<pt = ml + mCLAt = (pc + 0sub
 Introduction to Process Engineering and Design

where, <Z»(, = mX = heat duty for condensation

0sub = mCL AT = heat duty for subcooling
m = 10 900 kg/h = 3.0278 kg/s
A = Latent heat of vaporization of methyl ethyl ketone (MEK) at condensa-
tion temperature
At condensation temperature of pure MEK vapour
Py =pt= 13.73 kPa g = 115.055 kPa a = 863 torr a
Antoine equation4 for methyl ethyl ketone

i p = 16.5986
In 3150.42
v
T- 36.65
where pv is in torr and 7 in K
pv = pl = 863 torr T = 356.87 K = 83.870C
From Table 3-179 of Ref. 2,
Amek al 78.20C = 105.93 kcal/kg = 443.5 kJ/kg
Value of Amek is required at 83.870C.
Using Watson relation,

/. -p n0.38
i — ir->
A2=A|
1-7r\

Tl. = reduced temperature = 7/7c

Tc of MEK = 535.6 K

,0.38
(83.87 + 273.15)
535.6
A at 83.870C = ^ 2oC
(78.2 + 273.15)
1-
535.6

As3.87°C = 443.5 x 0.9882 = 438.27 kJ/kg

= ml = 3.0278 x 438.27 = 1327 kW
^ = mCL(83.87 - 60)

(83.87 + 60)
Specific heat of MEK liquid at = 720C:
Process Engineering Channel

CL = 2.298 kJ/(kg • 0C) (From Table 3-184 of Ref. 2)

0sub = 3.0278 x 2.298 x (83.87 - 60) = 166 kW
<p, = (t>c + 0sub = 1327 + 166 = 1493 kW
Energy Balance
0 = mwCpw (r0 - 32)
Fixing the outlet temperature of cooling water as 40oC,
@ProcessEng

mass flow rate of cooling water required

(p, 1493
=== 44 5746 k8/s
-
 Process Design of Heat Exchangers

First trial calculations:

Using Table 6.7, let overall heat transfer coefficients be
for condensation Uc = 800 W/(m2 ■ 0C)
for subcooling 17sub = 200 W/(m2 • 0C)
Assuming that entire flow of cooling water is first utilized for subcooling and then for
condensation.

0suh = 'kyCpJf - 32)

where t' = intermediate temperature of cooling water
166 = 44.5746 x 4.1868 x (r' - 32)
t' = 32.890C 83.87 > 83.87
LMTD for condensation:
ATJ" = 83.87 - 32.89 = 50.98oC 40
= 83.87 -40 = 43.870C
32.89
50.98-43.87
A'4 = = 47.3360C
50.98 Fig. 6.17(a)
In
43.87
for condensation of pure component R = 0 and 4=1, hence LMTD = MTD
LMTD for subcooling:
A'TJ- = 83.87 - 32.89 = 50.98oC 83.87
= 60- 32 = 280C
60
50.98 - 28
0
A4 = = 38.349 C
50.98 32.89
In 32
28
Assuming that subcooling will take place
Fig. 6.17(b)
in the perfect counter current manner.
4 = 1, hence LMTD = MTD
Area based on assumed values of U:
For condensation:

<Pc 1327x1000
A = = 35.042 m2
£4 AT 800 x 47.336
For subcooling:
Process Engineering Channel

4ub 166x1000
ASub - = 21.643 m2
^sub A'4suh 200 x 38.349
Total area A = Ac + Asub = 56.685 m2

Asub 21.643
= 0.3818 and Asub < Ac
A 56.685
@ProcessEng

Based on the selected values of overall coefficients, area required for subcooling
(Asub) is less than area required for condensation (A(.). Hence to get the smaller size of
heat exchanger horizontal position is selected. Ideally in such a case heat exchanger
should be designed for both positions and the position which requires lesser heat trans-
fer area should be selected.
 Introduction to Process Engineering and Design

Area provided for the first trial calculation

A = 56.685 m2 - N,7t(](lL
Choose 3/4 on OD (19.05 mm OD), 6 ft (1.83 m) long tubes

/\ ^ 56.685
N, = = ——" =518 tubes
nd0L (^-x 0.019 05x1.83)
Shell side fluid is a clean fluid, hence, select triangular pitch arrangement
P, = 1.25 d0 = 23.8125 mm
Number of tube side passes = 2 (for lsl trial calculations)
Tube bundle diameter:

'N,-
Db = d0 (6.1)
\k\ J

= 19.051 I2'207 (Using Table 6.2)

0.249
= 607 mm
Select a fixed tube sheet heat exchanger.
Let clearance between shell ID and = 13 mm
Shell inside diameter = 620 mm
Calculation of tube side heat transfer coefficient:

o, = -^ x - J2 = — x - (0.015 748)2 = 0.050 45 m2

' Np A 2 4

(From Table 11.2, of Ref. 2 for 16 BWG tube d, = 15.748 mm)

Tube side mass velocity.

^ m 44.5746 000 C/, , 2 n

G, = — = = 883.54 kg/(mz • s)
a, 0.050 45

«,=
P
Process Engineering Channel

883.54
= 0.89 m/s < I m/s
992.9
To avoid the excessive fouling it is recommended to keep the velocity of water greater
than 1 m/s.
Increase the number of tube side passes from 2 to 4.
for Np = 4, a, = 0.025 22 m2
@ProcessEng

D, = 19.05 (Table 6.2)

v 0.1757
= 630 mm
Let clearance between shell ID and Dh= 15 mm
 Process Design of Heat Exchangers 187

Shell inside diameter = 645 mm (revised)

44.5746 „ 2
G, = = 1767.43 kg/(m ■ s)
0.025 22
u, = 1.78 m/s

diG,
Re =

Viscosity of water at 360C, /2 = 0.72 cP = 0.72 xlO 3

kg/(m • s)

0.015 748x1767.43
Re = "\—3 = 38 657.6
0.72x10"

Prandtl number
Thermal conductivity of water at 360C, k = 0.6228 W/(m • C)

Cpu 4.1868 x (0.72 x 10-3) lu

iqS
Pr= -^- = -x
k 0.6228 1
= 4.84
Using Dittus-Bolter equation

. ^ V'-'4
= 0.023 Re0 9, Pr033 (6.19)
k /

/ \0.I4
P
Neglecting
P /
\r-w

0.023x0.6228
h: = x (38 657.6) x (4.84)a33
0.015 748
= 7155.5 W(m2 ■ 0C)
Shell side coefficient:
(a) For condensation zone, hco:
Calculation for mean temperature of condensate film:
Let tw = Tube wall temperature, 0C
hco = 1500 W/(m2 ■ 0C) (assumed for 1st trial calculation)
Process Engineering Channel

At steady state
Heat transfer rate through condensate film = overall rate of heat transfer
hCoAc.(tc-tJ=UL.AL.(tc-tav)
where, tc = Condensation temperature of vapour on shell side, 0C
0
rav = Average tube side fluid temperature for condensation zone, C

(32.89 + 40)
@ProcessEng

1500(83.87-0 = 800 83.87 -

= 58.5770C
Mean temperature of condensate film

tc+tw (83.87 + 58.577)

= 71.220C
 Introduction to Process Engineering and Design

Physical properties of liquid condensate at 71.220C

Viscosity of liquid MEK at 71.22 0C, iuL = 0.32 cP = 0.32 x lO"3 kg/(m • s)
Density of liquid MEK at 71.22 0C, pL = 805 kg/m3
Thermal conductivity of liquid MEK at 71.22 0C, kL = 0A 73 W/(m • 0C)
Shell side condensation coefficient with horizontal position
1/3
Pl(Pl ~ Pv) 8 -1/6
hco = 0.95 kL N (6.37)
r
PL h
Acceleration of gravity g = 9.81 m/s2

PM PM
Density of vapour pv = x (.v for standard conditions)
RT P
'sV
y
s

863x72 273
A = x
(273 + 83.87) 760x22.414
pv = 2.97 kg/m3

W (10900/3600)
h = = 3.194 x lO"3 kg/(m • s)
LN. (1.83x518)
Average number of tubes in vertical rows

Db
Nr = 2/3 N' = —
3

2 630
= —x = 17.64 s 18
3 23.8125

1/3
805 x (805-2.79) x 9.81
A =0.95 x 0.173 -1/6
x (18)
3 -3
0.32 x 10" x 3.194 xlO

= 1864.86 W/(m2 • 0C)

hco is close enough to assume value of hc0. Hence, correction in the value of tw is not
required.
(b) For subcooling zone, //osub:
Process Engineering Channel

With horizontal position, subcooling is taking place via natural convection only for
which reliable correlations are not available. Based on Kern's recommendation (Ref. 5),
homb for horizontal position.
/W, = 50 Btu/(h • ft2 • 0F)
= 283.77 W/(m2 • 0C)
Overall Heat Transfer Coefficient for Condensation:
@ProcessEng

1
lJ
oc = (6.42)
d
1 + J_ + " ln(^' ldi ' +
d
o{ \
+
h.
"OC h..od 2k..
—' V
W d: \ hi /
"•( d
i h
id
From Table 6.9,
For organic vapours, hod = 10 000 W/(m2 • 0C)
For cooling water, hid = 4000 W/(m2 • 0C)
 Process Design of Heat Exchangers

With methyl ethyl ketone and cooling water, stainless steel-304, is a suitable material for
the tube.
Thermal conductivity of SS-304 material, kw = 16.3 W/(m • 0C)
/
19.05 ^
0.019 05 In
1 1 15.748 19.05 .. 1
+ + + X
Uoc 1864.86 10 000 2x16.3 15.748 7155.5

19.05 1
+ x
15.748 4000
2 0
Uoc = 820.38 W/m • C)
Heat transfer area required for condensation

0cond 1327x1000
A,...
£T
=
Uoc x ATmc 820.38 x 47.336

Acr = 34.17 m2
Overall Heat Transfer Coefficient for Subcooling:

= <6 42)
i | i | dMdjd,) tdc \ ~d~l '
h
Ksub od 2kw d, hid di hi

1
^osub
1 i 0.019 05 ln(19.05/15.748) 19.05 1
_j 1 x.
283.77 10000 2x16.3 15.748 4000
| 19.05
15.748x7155.5

[/„sllb = 237.72 W/(m2-0C)

Heat transfer area required for subcooling

(psuh 166x1000
ASubr = — = = 18.21 m2
^osub x ATmsub 237.72x38.349
Total heat transfer area required
Alr = Acr + Asubr = 34.17 + 18.21 =52.38 m2
Process Engineering Channel

4
56 685
'P"' - = 1.082
A,req 52.38

or % Excess heat transfer area = (1.082 - 1) x 100 = 8.2%

% Excess heat transfer area should be atleast 10%. Hence, to increase the value of heat
transfer area, increase the tube length. New value of tube length is
@ProcessEng

L = 1.83 x = 1.95 m
1.082
Let new or revised tube length L = 2 m

2 ■?
Heat transfer area provided Anril = x 56.685 = 61.95 nr
pro
1.83
 Introduction to Process Engineering and Design

Revised value of shell side condensation coefficient

1/3
1^ ^ L
1/3
hoc = | — | x 1864.86 = 1920.9 W/(m2 ■ 0C)
1.83,
New value of Unc

I 1 1
+
Uoc 820.38 1864.86 1920.9
2 0
Uoc = 831 W/(m • C)

1327x1000
Alir = = 33.73 m2
831x47.336
As„b = 18.21 m2
Areci =51.94 m2

^fpro = A | OS = 1.1927

Areq 51.94

% Excess heat transfer area = (1.1927 - 1) x 100 = 19.27%

If the equal percentage of excess heat transfer area (19.27%) in both zones are provided
then.
Heat transfer area provided for condensation:
Ac,pro = 33.73 x 1.1927 = 40.23 m2
Heat transfer area provided for subcooling:
Asubpro = 18.21 x 1.1927 = 21.72 m2

= 21^2 = 0 35^
Apro 61.95
Hence, 35.06% of total heat transfer area should be provided for subcooling.
Assuming that tube will be uniformly distributed in the cross section of shell.

Aubpro Area of segment of cross section utilized for subcooling

Ajp,.,, Total cross sectional area of shell
Process Engineering Channel

xDf
0.3506 = —

x=- x0.3506 = 0.2754

4
From Table 1.19b of Ref. 2, for x: = 0.2754, h/D, = 0.382
@ProcessEng

Hence, 38.2% of shell inside diameter should be submerged in the pool of condensate to
faciltate subcooling.
This can be achieved by providing inverted U-seal (Fig. 6.18) height of inverted U-seal
from the base of shell ID
h = 0.382 x 645 = 246.4 mm
 Process Design of Heat Exchangers 191

Shell side pressure drop Aps: Hydrocarbon

Vapours
Shell side flow area
i
/; = 246.4 mm

sOV

where x'=\- — = \- 0.382 = 0.618

di Condensate
Let baffle spacing Bs = Shell ID = 645 mm Fig. 6.18 Detail of U-Seal

(23.8125-19.05)
As = x 0.645 x 0.645 x 0.618 = 0.051 42 m2
23.8125
Shell side velocity

11 s =
Pv

Shell side mass velocity, G, = — =

Gs 0.05142
Gs = 58.884 kg/(m2 ■ s)

58,884
ms = (GVp ) = =21.105 m/s
2.79
Equivalent diameter for triangular pitch arrangement

de=^(P,2-0.901dt)

1.1
(23.81252 - 0.907 x 19.052) = 13.736 mm
19.05

0.013 736x58.884
Re = = 73 530
1100 x 10~7 x 10_l

(Viscosity of MEK vapour at 83.870C = 1100 x 10~7 Poise)

From Fig. 6.15, for 25% cut segmental baffle
Shell side friction factor, Jj-= 0.0358
Process Engineering Channel

\-0.14
D, L Pv".2 ' P
Aps = 0.5 x 8 x 7 (6.41)
Kde B, 2

2 79 X 2U05
= 0.5 x 8 x 0.0358 f-^-Yx -
v 13.736 A 645 ) 2
@ProcessEng

= 129 56 Pa = 12.956 kPa < Apsmax (13.73 kPa)

To decrease the shell side pressure drop, increase the % baffle cut from 25% to 35%,
then for 35% cut segmental baffle
Jf = 0.03

0.03
Ap = x 12.956 = 10.86 kPa < A psmax (13.73 kPa)
0.0358
 Introduction to Process Engineering and Design

Tube side pressure drop, Ap,:

\/ \ -m
pu;
L p
8J / ( + 2.5 X (6.27)
A y K PW J /
L = 2000 mm, Np = 4, r/,- = 15.748 mm, p = 993.684 kg/nr, m, = 1.78 m/s
Re = 38 657.6, Jf = 3.41 x H)"3 (from Fig. 6.13)

x
993.684 xl.782
Apt = 4 x 8 x 3.41 x 10"3 x f 2000
] x 1 + 2.5 x
15.748y
Ap, = 37 558 Pa = 37.558 kPa < Aptmax (68.6 kPa)
Resulting Heat Exchanger Specifications:
1-4, fixed tube sheet shell and tube heat exchanger (BEM type).
Shell ID = 645 mm. Baffles: 35% cut segmental.
Baffle spacing = 645 mm,
Tube OD = 19.05 mm, 16 BWG, Tube length = 2000 mm,
A Pitch arrangement, P, = 1.25 dn, Number of tubes, = 518

6.5 CONDENSATION WITH NON-CONDENSABLES

For the design of this type of heat exchanger, methods available are: (i) Colburn
and Hougen method and (ii) Porter and Jaffreys method. But these methods are
complex requiring trial and error calculations. These methods consider both
resistances; resistance provided by heat transfer and diffusional resistance pro-
vided by mass transfer.
Approximate methods are also available for the same. In approximate methods
only the resistance, offered by heat transfer, is considered while mass transfer
resistance is neglected. Hence in these methods it is assumed that overall rate of
heat transfer in condensation with cooling of non-condensables is totally controlled
by heat transfer resistance. One of the approximate methods is Gilmore's equa-
tion"1.

1 1
+ (6.44)
h
c8 h, 0, h K
where, hcg = Heat transfer coefficient for condensation with cooling of non-
Process Engineering Channel

condensables, W/(m2 • 0C)

hc = Average condensate film coefficient, determined by using single
component condensation correlations, at the average condensate
'y
composition and total condensate loading, W/(m • 0C)
/2„ = Average gas film coefficient determined for the average vapour
gas mixture flow rate, W/(nr ■ 0C)
@ProcessEng

(pg = Total sensible heat transfer from vapour-gas mixture, kW

0, = Total heat transfer, kW
0,= Latent heat of vaporization + sensible heat for cooling the gas-
vapour mixture.
For non-condensables, present in vapour, guidelines given by Frank (Sec. 6.4)
may be followed.
 Process Design of Heat Exchangers 193 |

Example 6.3
Air saturated with u-hutanol vapour at 49 kPa g pressure and at 100oC temperature is to
be sent to shell and tube heat exchanger for recovering butanol. Air-butanol vapour
mixture is to be cooled to 50oC by cooling water which enters at 320C and leaves the
heat exchanger at 40oC.
Air flow rate (butanol free) = 500 NnrVh
Check that whether the shell and tube heat exchanger with following specifications is
suitable for the given duty earlier.
(i) Type of heat exchanger; BEM as per TEMA
(ii) Material of Construction of heat exchanger: SS-304
(hi) Shell ID = 387 mm
(iv) Tube OD = 19.05 mm
(v) Tube ID = 15.748 mm
(vi) Tube length = 1500 mm
(vii) Tube Pitch = 25.4 mm
(viii) Type of tube arrangement = Triangular
(ix) Number of tubes = 134
(x) Number of tube side passes = 4
(xi) Number of shell side passes = one
(xii) Baffle type = 25% cut segmental
(xiii) Baffle spacing =120 mm
Properties of fluids and material:
(a) Thermal conductivity of SS-304, kw = 16 W7(m • 0C)
(b) Antoine equation4 for butanol
3137.02
In pv = 17.2160- where pv is in torr and T is in K.
T - 94.43
(c) Latent heat of vaporization of butanol at 750C, = 642 kJ/kg
(d) Physical properties of butanol condensate at average condensate film temperature
Specific heat, CL = 2.8763 kJ/(kg ■ 0C)
Viscosity, nL = 0.95 cP = 0.95 mPa • s
Thermal conductivity, kL = 0.168 W/(m • 0C)
Density, pL = 810 kg/m3
(e) Physical properties of air-butanol vapour mixture of average composition at 750C
and at the operating pressure:
Process Engineering Channel

Specific heat, Cp = 1.3043 kJ/(kg ■ 0C)

Viscosity, p = 0.0174 cP or mPa • s
Thermal conductivity, k = 0.03 W/(m ■ K)
Density, p = 2.012 kg/m3
(f) Physical properties of cooling water
CLw = 4.1868 kJ/(kg • 0C)
p,,, = 0.72 cP
@ProcessEng

kw = 0.63 W/(m ■ K)
p.,, = 1000 kg/m3
(g) Fouling coefficients hod = hjd = 5000 W/(m2 ■ 0C)
Solution:
Heat duty equation for the given case
0, = ma cpa Al + mv Cpv AT + mnc A = (m(l + mv) Cpav At + mnc A
 194 Introduction to Process Engineering and Design

where, </), = Heat duty, kW

ma = Mass flow rate of air, kg/s
mv = Average mass flow rate of butanol vapour, kg/s
mBc = Condensation rate of butanol, kg/s
Cpa = Specific heat of air, kJ/(kg ■ 0C)
Cpv = Specific heat of butanol vapour, kJ/(kg • 0C)
A = Latent heat of vaporization of butanol, kJ/kg
C^v = Specific heat of Air-butanol vapour mixture, kJ/(kg • 0C)
Density of air at normal condition

pM pM Ts
Pair = = X (5 for standard conditions)
RT T psVs

1x29 273
Pair = X = 1.1853 kg/nr
(273 + 25) 1x22.414

ma = 500 x 1.853 = 592.65 kg/h = 0.1646 kg/s

mv = Average flow rate of butanol vapour

nivi + nix

where, mvi = Mass flow rate of butanol vapour at inlet, kg/s

mv0 = Mass flow rate of Butanol vapour at outlet, kg/s
At inlet, air is saturated with butanol vapour at 100oC temperature and at 49 kPa g
pressure.
Vapour pressure of butanol at 100oC = pv = pv
where pv = partial pressure of butanol vapour at inlet

3137.02
At 100oC In pv = 17.216-
T - 94.43
for T = 100 + 273 = 373 K, pv = 385.617 ton-
Mole fraction of butanol vapour in incoming air-butanol mixture:

Pv = 385.617
Process Engineering Channel

Pi Pt
p, = 49 kPa g = 49 + 101.325 = 150.325 kPa a = 1127.53 torr a

385.617
» = = 0.342
1127.53

tlr.
mvl = y,- x x molar mass of butanol (C^gOH)
@ProcessEng

{ha = molar flow rate of air)

/
' 0.1646
29
= 0.342 x x 74 = 0.2183 kg/s
1-0.342
 Process Design of Heat Exchangers

m
v0 = yo x molar mass of butanol
i-yo
y0 = Mole fraction of butanol vapour in air-butanol vapour mixture at outlet

Pv Pv
P, P,
At the outlet also air is saturated with butanol vapour.

Pv = Pv - vapour pressure of butanol at 50oC temperature

For r= 273 + 50 = 323 K, p', = 32.8336 torr
p,' = Operating pressure of air - Vapour mixture of butanol at outlet = pl - Api
where, Aps = Shell side pressure drop.
Assume shell side pressure drop Aps =13.8 kPa (2 psi)
p,' = 150.325 - 13.8 = 136.525 kPa a = 1024 torr a

32.8336
^ = = 0.032 06
1024

0.16463
29 J
m„„ = 0.032 06 x 74 = 0.0139 kg/s
1 - 0.032 06

0.2183 + 0.0139
m„V = = 0.1161 kg/s

mBC = Condensation rate of butanol = mvi - mvo

= 0.2183 - 0.0139 = 0.2044 kg/s
(p, = (0.1646 + 0.1161) x 1.3043 (100 - 50) + 0.2044 x 642
= 149.53 kW
Heat balance: 100oC
<t>, = rnwCpw At 50 C
149.53 = mw x 4.1868 x (40 - 32)
40oC
mH, = 4.4643 kg/s = 16.07 m3/h 32 C
MTD: A'4=F,xA'4 Eq. (6.11)
Process Engineering Channel

ATf,, Fig. 6.19

All - AH,
A "4 = , AH = 100 - 40 = 60oC, AH = 50 - 32 = 180C
N
'AT,
In
AH,

60-18
@ProcessEng

AH, = —: = 34.880C

F, = LMTD correction factor

% -4 h ~ri
R = and S=
h ~h %-h
 196 Introduction to Process Engineering and Design

100-50 50 40-32 «
R = = — =6.25,5= = — =0.1176
40-32 8 100-32 68

From Fig. 6.11 for 1-4 shell and side tube heat exchanger,
' F, = 0.96
A?,, = 0.96 x 34.880C = 33.4850C
Tube side heat transfer coefficient, /?,•:

N
Tube side flow area, a, = ' x^-d} (6.20)
Np 4

134
x - (0.015 748)2 = 6.525 x K)"3 m2
4 4

ihw 4.4643
Tube side mass velocity, Gr =
a. 6.525x10 -3

= 648.2 kg/(m2 • s)

G, 684.2
Tube side linear velocity ur = — = = 0.6842 m/s

d.G, 0.015 748x684.2

Re =
P \-3
0.72x10"

= 14 965

CPF 4.1868 x (0.72 xl0_3)xl03

Pr =
0.63
Pr = 4.7849
/ nO.14
h: d: P
033
= 0.023 Re^Pr (6.19)
PW

h: = 0.023 x - — x (14 965)0"8 x (4.7849)U0.33

0 63 JJ
x 1
0.015 748
Process Engineering Channel

h, = 3374.9 W/(m2 • 0C)

Shell side heat transfer coefficient, h0\

1
=-L+ * 1 (6.44)
K
*0 K*
eg KC h
rl K
-g
Mean condensate film coefficient, hc:
@ProcessEng

For horizontal position, modified Nusselt's equation is applicable

1/3
Pl(PL-P\')8
hc = 0.95 kL xN. -1/6 (6.37)
Pl*i,
 Process Design of Heat Exchangers

W m
C BC 0.2044
= 1.017 x J O"3 kg/(m - s)
LN, LN, 1.5x134

D T.Q'l
Nr = 2/3N', N' = — = = 15
P, 25.4
N,. = 10

P, +P,
M
pM
Density of vapour, pv =
RT RT

150.325 + 136.525
x 74
273
x
( 273 + 75) 101.325x22.414

pv = 3.666 kg/m3

/ \l/3
810(810-3.666) x 9.81
/? =0.95x0.168 x -1/6
-3 -3
(10)
v 0.95 x 10 x 1.017 xlO
,2 o,
hc = 2042.9 W/(m ■ 0C)
Average gas film coefficient, h^:
{Pt-d0)BsDs
Shell side flow area, A. = (6.29)

25.4-19.05
x 0.12x0.387 = 0.011 61 m2
25.4
Equivalent diameter for triangular pitch arrangement

d = —(P,2 - 0.907J 2) = ———(0.02542 - 0.907 x 0.019 052)

e
d0 0.019 05

= 0.018 247 m
Shell side mass velocity Gs:
Process Engineering Channel

ms (0.1646 + 0.1161)
G5 = = 24.18 kg/(m2 • s)
0.01161

deGs 0.018 247x24.18

Reynolds number, Re =
P 0.0174x10 -3
@ProcessEng

= 25 357

cpP 1.3043x0.0174x 10"3 xlO3

Pr =
k 0.03
= 0.7565
 198 Introduction to Process Engineering and Design

Gas film coefficient can be determined by following correlation.

0.14
d„ _R_
0 55 m
h„ = 0.36 Re Pr (6.35)
Pw /

0.03 1/3 1
hn = 0.36 x x (25 357)a55 x (0.7565)x si
0.018 247 Pw
= 142.59 W/(m2 ■ s)

_1_ = _L + ^_L- I 1
+ X (6.44)
hn h0 <pt hg 2042.9 0, 142.59

where, 0g = (ma + mv) Cp.JV At = (0.1646 + 0.1161) x 1.3043 (100 - 50) = 18.306 kW
0, = 149.53 kW

1 _ 1 18.306 v I
— i X
h.. 2042.9 149.53 142.59
/i =741.8 W/(m2- 0C)
Overall heat transfer coefficient U.
d
1 1 | 1 | dl) In (d0!dj) | <> 1 | o 1
(6.42)
Uo h0 hod 2km di h, di hid
Thermal conductivity of tube material (SS-304), km = 16 W/(m ■ 0C)

19.05
u.uiy uo x mi
1 1 15.748) 19.05
+ H X
f/„ 741.8 5000 2x16 15.748 3374.9

19.05 1
x
15.748 5000
2 0
U0 = 442.13 W/(m • C)
Heat transfer area required, Aor:

0; 149.53 xlO3
An.. =
442.13x33.485
Process Engineering Channel

= 10.1 m2
Heat transfer area provided,
Aopro = N,nd0L = 134 x ^rx 0.019 05 x 1.5 = 12.0293 m2

4 pro
12 0293
Exces heat transfer area = 1 x 100= I - -1 I X 100= 19.1'
4r 10.1
@ProcessEng

Hence heat transfer area provided by heat exchanger is sufficient for the given duty.
Shell side pressure drop Aps:

/ \ / \ -0.14
'D^ L P.V«T P
Aps = 87, (6.40)
U J 4 7 2 vP.. J
 Process Design of Heat Exchangers

Re = 253 57, Jf = 4.2 x 10" (From Fig. 6.15)

L = 1500 mm, Bs = 120 mm, Ds = 387 mm, de = 18.247 mm
ps = Density of shell side fluid (air - vapour mixture)

pM,
Ps =
RT

» +^
Average mole fraction of butanol vapour, yav =

0.342 + 0.032 06
3'av = 0.187 03

May = yav x molar mass of butonal + (1 -yav) x molar mass of air

Mav = 0.187 03 x 74 + (1 - 0.187 03) x 29 = 37.4163 kg/kmol

150.325 + 136.525
x 37.4163
pMav 273
Ps = x
RT (273 + 75) 101.325x22.414

ps = 1.8537 kg/m3
us = shell side linear velocity

(A 24.18
= 13.04 m/s
Ps 1.8537

387 V1500 "l 1.8537 x 13.04

An =8x4.2 x 10,-2 x xl
18.247 A 120
= 14 039 Pa = 14.04 kPa
Calculated shell side pressure drop (Aps= 14.04 kPa) is very close to optimum pressure
drop (APopl = 13.8 kPa). Hence it is satisfactory.
Tube side pressure drop. A/?,:

/ \
_L P_ P<
Ap, = N 87, + 2.5 (6.27)
d
\ i / , Pw
Process Engineering Channel

Np = 4, L= 1500 mm, d, = 15.748 mm, 1000 kg/m3- u, = 0.6842 m/s

for Re = 14 965 from Fig. 6.13 7.= 4.3 x lO"3

1500 1000 x 0.6842-'

Apt=4 8x4.3x10 -3 x 1 + 2.5 x
15.748
Ap, = 5408.4 Pa = 5.408 kPa < Ap, max (68 kPa)
@ProcessEng

Hence, tube side pressure drop is very much less than maximum or optimum pressure
drop.

Considering % excess heat transfer area, Aps and Ap,, given shell and tube
heat exchanger is suitable for the required heat transfer duty. If the given shell
and tube heat exchanger is at design stage (not fabricated), then number of tube
side passes could be increased from 4 to 8 because of the following reasons:
 Introduction to Process Engineering and Design

(i) Cooling water has a tendency to foul. To avoid the excessive fouling it is
better to keep the velocity of cooling water more than 1 m/s, preferably
near 2 m/s.
(ii) Increase in tube side passes will increase the tube side heat transfer
coefficient and overall coefficient. Consequently, it will decrease the required
heat transfer area and hence the fixed cost. However, it will increase the
operating cost for pumping the tube side fluid. Also in the given case, overall
heat transfer coefficient is controlled by shell side heat transfer coefficient
hence increase in number of tube side passes has little effect on the value of
overall heat transfer coefficient.

6.6 MULTICOMPONENT CONDENSATION

In condensation of pure component (Example: condensation of pure ethanol va-

pour), condensation is taking place in isothermal manner or at constant tempera-
ture (degree of freedom =1). While in case of multicomponent condensation,
during the condensation, temperature decreases from dew point to bubble point
temperature, except in the following cases.
(a) Condensation of the vapour mixture of two immiscible components (immis-
cible in liquid phases) Example: Vapour mixture of toluene and water
vapour.
(b) Condensation of the azeotropic vapour mixture.
For example, condensation of vapour mixture containing 89.4% (by mole)
ethanol vapour and 10.6% (by mole) steam at 1 atm pressure.
In condensation of vapour mixture of miscible components (miscible in liquid
phase), condensation starts from dew point temperature and terminates at bubble
point temperature. For the calculations of dew point, bubble point and composi-
tions of vapour phase and liquid phase in between dew point and bubble point,
vapour liquid equilibrium data at operating pressure for the given system is re-
quired.
For finding the vapour-liquid equilibrium data from dew point to bubble point
at operating pressure, there are three options.
(i) Find the VLE data by conducting the actual experiment. Particularly if the
operating pressure is atmospheric or vacuum, then determination of VLE
Process Engineering Channel

data via actual experiment is easier.

(ii) Find the VLE data from literature.
(iii) Find the VLE data by theoretical equation.
T/ = Kfr (6.45)
where, yi = Mole fraction of component i in vapour phase.
Xj = Mole fraction of component i in liquid phase
@ProcessEng

Ki = Equilibrium constant for component i,

Kj is a function of operating pressure, temperature as well as of composition.

For an ideal solution (i.e. the solution following Raoult's law), = f{T, p)
P,
(6.46)
 Process Design of Heat Exchangers 201

where, pvj = Vapour pressure of pure component i at the operating temperature

pt = Operating pressure
For non-ideal vapour liquid equilibrium

l' Pvi 'Y i r/rjn \

Ki= —— =f(T,p) (6.47)
P, Q
where jj = Activity coefficient of component i in liquid phase,
(pi = Fugacity coefficient of component i in vapour phase.
If solution can be considered as ideal solution then ^ = 1. (Example: For the
liquid mixture of benzene and toluene yis = 1). If vapour mixture can be consid-
ered as ideal gas mixture then 0, = 1 (Example: Vapour mixture of benzene and
hexane at 1 atm pressure)
In the design of multi-component condenser calculations, weighted tempera-
ture difference is important instead of mean temperature difference (MTD = LMTD
xF,).
To calculate weighted temperature difference, entire condensing range is di-
vided in different small intervals. The weighted temperature difference is calcu-
lated by following equation.

Z0
Weighted At - (6.48)

where, (j) = Heat load for an interval

Atlv = Average temperature difference for the interval
In condensing multicomponent mixture from dew point to bubble point, va-
pour and condensate are also cooled by sensible heat transfer. Vapour is cooled
simultaneously during condensation but cooling of condensate must be facili-
tated by providing the inverted U seal or by using a dam baffle (Fig. 6.2(f)).
Cooling of condensate formed at or near the dew point heat the condensate at or
near the bubble point in condensate collecting vessel and regenerate the vapour.
Hence it is necessary to cool the condensate simultaneously with vapour mixure
from the dew point to bubble point in the condenser to avoid the regeneration of
vapour from condensate and for the cooling of condensate certain number of
Process Engineering Channel

tubes must be submerged in the pool of condensate which is assured by using

inverted U seal or dam baffle.
Design of multicomponent condenser is illustrated by the following example.

Example 6.4
Overhead vapour flows at the rate of 500 kmol/h from a distillation column at 4 atm a. It
contains saturated hydrocarbons and has the composition; 30% /7-C3H8, 25%
@ProcessEng

20% n—C5H|2 and 25% n-C6H|4 (mole basis). It is to be condensed in a condenser.

Permissible pressure drop in the condenser is 13.8 kPa.
(a) Determine the condensing range.
(b) Compute the condensing curve.
(c) Compute the weighted average temperature difference and
(d) Design and specify a suitable condenser.
 202 Introduction to Process Engineering and Design

Solution:

Table 6.10 Composition of Overhead Vapour

Component mole % kmol/h Molar kg/h mass %

(Zj X 100) mass
;7-C2H8 30 150 44 6600 20.75
"-CAq 25 125 58 7250 22.80
20 100 72 7200 22.64
n-C6H14 25 125 86 10750 33.81
Total 100 500 31800 100.00

Solution:
(a) Condensing range: Condensation starts from dew point and terminates at bubble
point.
Dew point:

y.
At dew point, X-~ = ' an(: z =
^ i (6.49)
K:
Value of equilibrium constants A", for hydrocarbons can be obtained from Fig. 6.20.
This calculation requires trial and error.
Assume, t = 810C and p-A atm a,
K
c,H8 -5-7' KCc4H|0
H = 2.3, ^c5//l2 - 0-89, Kr = 0.4

03 + 0^5+ _02_+025 01^1

+ + +
kj ~ 5.7 2.3 0.89 0.4 " '
Dew point temperature of vapour mixture = 810C at 4 atm a pressure
At bubble point, = 1, where x,- = z,- (6.50)
Assume r = 310C

KCjttg
c H = 2.5, Kr- ul0 = 0.74. Kl
l-4H HI2 = 0.24, Kc
c5h c5"I4
H = 0.085

ILKjXj = (0.3 x 2.5 + 0.25 x 0.74 + 0.20 x 0.24 + 0.25 x 0.085) = 1.00
Bubble point of vapour mixture = 310C
Therefore, the condensation range is from 810C to 310C
Process Engineering Channel

(b) Condensing curve:

Divide the condensation range in five intervals; say STC to 70oC, 70oC to 60oC,
60oC to 50oC, 50oC to 40oC and 40oC to 310C.
Equilibrium constant A", values (From Fig. 6.20):

Table 6.1 I Equilibrium Constants Ki Values (from Fig. 6.20)

@ProcessEng

Ki
Component 8I0C 70oC 60oC 50oC 40oC 310C
c,h8 5.7 4.9 4.2 3.6 3.0 2.5
QH|0 2.3 1.75 1.5 1.2 0.95 0.74
C5HI4 0.89 0.7 0.56 0.42 0.32 0.24
C6H,4 0.4 0.3 0.23 0.17 0.12 0.085
 Process Design of Heat Exchangers

aT %C>
5 ?■
- 0- o z

-200
"190
-180
-170
-160
-150
-140
-130
-120
-110
-100

-80
0- u
-70

I
z—40

3000
3500 z—20
4000
oo\s

Xt m 2= Bc -0
a. c_
--5

Fig. 6.20 Kj Values for Hydrocarbons at High Temperatures8

(Reproduced with the Permission of the American Institute of Chemical Engineers,
USA.)

Let f = Total molar flow rate of saturated vapour mixture entering to condenser
= 500 kmol/h.
Process Engineering Channel

First interval:
Let, L, = Total moles of condensate at the exist of 1st interval (at 70oC)
V] = Total moles of vapour at the exist of 1st interval
F = L] + Vi
Let C, = Moles of condensate formed in the interval, for first interval C, = L]
Component balance F z, = L/X,- + F,)', (6.51)
@ProcessEng

Ki
V, = (6.52)
V|
1 + . k" (=70°C)
**•/'

Assume the value of F|/L| and find the value of by Eq. (6.52). Then XL|X(- = L,,
F-Li = V{, F|/L| = ? Value of Vl/Li obtained at the end of calculations should be same
as the assumed one. So it requires trial and error calculations.
 Introduction to Process Engineering and Design

Table 6.12 Flash Calculations for Range 8/0C to 70oC

Component Fzi Ki (= 70oC) L x

i i Cixi A,-, kJ/kg Cmpi kJ/ C,. kJ/
(kmol ■ K) (kg • K)
C3H8 150 4.90 10.917 10.917 230.27 84.253 3.12
C4H,O 125 1.75 22.522 22.522 301.450 111.08 2.70
c5hI2 100 0.70 35.460 35.460 303.540 137.08 2.51
C6HI4 125 0.30 70.225 70.225 309.820 163.17 2.43
Total 500 139.124 139.124

V,
Assume — = 2.6
A

150 125 100 125

■+ + ■+ = 139.124
1 + 2.6x4.9 1 + 2.6x1.75 1 + 2.6x0.7 1 + 2.6x0.3

L, = 139.124 kmol/h
V, = F-L] = 500 - 139.124 = 360.876 kmol/h

v
i 360.876
= 2.5939
L| 139.124

difference = 2.6 - 2.59390 = 0.006 < 0.01

Y}_
= 2.6

Values of A, at average temperature (75.50C)

These are obtained from Fig. 3.9 of Ref. 2. Specific heat of vapour are determined by
using following equation.
C3HS Cmpi = -5.338 + 310.24 x lO"3 T- 164.64 x I0-6r2 + 34.691 x 10-9r3
c4ul0 Cmpi = -1.779 + 386.96 x IO"3 7 - 193.25 x 10"6 72 + 34.833 x 10"9 73
C5H12 Cmpi = -3.411 + 485.01 x lO-3 7- 251.94 x W6!2 + 48.677 x lO-9 73
C6HI4 Cmpi = -4.738 + 582.41 x lO"3 7- 310.64 x 10-672 + 62.923 x 10-973
where Cmpi are in kJ/(kmol K) and 7 is in K (Table 5.1 of Ref. 9)
Process Engineering Channel

Specific heat of liquids are obtained from Fig. 4 of Ref. 5 at average temperature
(75.50C).
Values of Cmp and CL are at 1 bar a in ideal state. However, these are not significantly
affected under pressure upto 10 bar.
For the interval 810C to 70oC

Fzi + Vi yi ^ 0 + L, jr,- ^
@ProcessEng

= ZCJXJA, + S C„,„,-A/
mpi +E Cu ^
I 2 J
0, = (10.917 x 230.27 x 44 + 22.522 x 301.45 x 58 + 35.46 x 303.54 x 72

150 + (150-10.917)
+ 70.225 x 309.82 x 86) + x 84.253 x 11
 Process Design of Heat Exchangers

125+ (125-22.522)
+ x 111.08 x 11

f 100+ (100-35.46)
+ x 137.08 x 11

125+ (125-70.225) 10 917

+ x 163.17 x 11 + ——— (3.12 x 44) x 1

22 522
+ - x (2.7 x 58) x 11 + (2.51 x72)x 11
2

70.225
+ x (2.43 x 86) x 11
2
</), = 3150 472.1 + 558 323.68 + 143 602.7
</>, = 3852 398.5 kJ/h = 1070.1 kW
Second interval:

Table 6.13 Flash Calculations for Range 70oC to 60oC

v
Component iyi(=Fzi-Llxi) Kj (=60°C) L x
2 , V2yii= Fzi-L^i) c2 x;

CjHg 139.083 4.2 24.834 125.166 13.917

C4H10 102.478 1.5 44.643 80.357 22.121
C5H12 64.540 0.56 59.810 40.190 24.350
C6H,4 54.775 0.23 97.962 27.038 27.737
Total 360.876 227.25 272.75 88.125

For the second interval let L2 is total moles of condensate leaving at 60oC and C2 is
moles of condensate formed in second interval.

Ci — ^
V
2
+
' 7 ^((=60oC)
Process Engineering Channel

^2

where, = Total moles of vapour at 60oC, leaving the second interval

150 125 100 125

Lj = ILjXI = +
V-, V. V, v.
1 + —x4.2 1 + —xl.5 1 + —xo.56 1 + —xO.23
L2 Lo L2
@ProcessEng

V
2
Assume — = 1.2
^2
L2 = IL2jr,. = 24.834 + 44.643 + 59.81 + 97.962 = 227.25 kmol/h
F=V2 + L2
V2=F-L2 = 500 - 227.25 = 272.75 kmol/h
 206 Introduction to Process Engineering and Design

v
2 272.75 . 0 . .>
— = = 1.2 (check)
227.25

= Ki - L2xr c x
2 i= Vtfi -

Table 6.14 Properties at 650C

Component A,-, kJ/mol Cmpi, kJ/(kmol • K) Cu, kJ/(kmol - K)

11 605.81 82.053 132.64

C4Hi0 18 212.58 108.28 150.56
C5HI2 22 608.72 133.62 177.86
C6H]4 28 445.12 159.06 205.24

For the interval 70 to 60oC

V. V; + V-, V; L x
\ i + L x
2 i
1 2
02 = +I ' ' Cmpi Af + Z Cu Ar

02 = (13.917 x 11 605.81 + 22.121 x 18 212.58 + 24.35 x 22 608.72

+ 27.737x28 445.12)

139.083 + 125.166 ' 102.478 + 80.357 x

+ x 82.053 x 10 + x 108.28x 10

64.54 + 40.19 54.775 + 27.038

+ x 133.62 x 10 + x 159.06 x 10

10.917 + 24.834 22.522 + 44.643

+ x 132.64 x 10 + x 150.56 x 10

35.46 + 59.81 70.225+97.962

+ x 177.86 x 10 + x 205.24 x 10

02 = 1903 903.2 + 342 435 + 331 589

Process Engineering Channel

02 = 2577 927.2 kJ/h = 716.1 kW

Table 6.15 Flash Calculations for Range 60oC to 50oC

Component %,• Ki (= 50°C» L2Xi L x

3 i v
^i C x
3 i
C3H8 125.166 3.60 24.834 48.5751 101.425 23.741
C4H10 80.357 1.20 44.643 73.7028 51.297 29.060
@ProcessEng

C5H12 40.190 0.42 59.810 80.4117 19.588 20.600

C6HI4 27.038 0.17 97.962 113.7812 11.220 15.820
Total 272.750 227.250 316.4708 183.530 89.220

Value of L^x,; V3yi and of above table are obtained via following calculation.
 Process Design of Heat Exchangers 207

L3 is total mole of condensate at 50oC.

L3 = =Z

(= 50° C)

150 125 100 125

L3 = ZLjX, = ■+ •+
^3 V3
+ —x3.6 1 + —xl.2 x 0.42 1 + —xO.17
^3 L3 Li

^3
Trial: Assume — = 0.58
Li

150 125 100 125

L3 = ZLjXj = •+
1 + 0.58x3.6 1 + 0.58x1.2 1 + 0.58x0.42 1 + 0.58x0.17

L3 = IL3A-,. = 48.5751 + 73.7028 + 80.4117 + 113.7812 = 316.4708 kmol/h

I/3 = 500 - 316.4708 = 183.5292 kmol/h

= 0.5799 = 0.58 (Check)

C3X; = (7^)3 - (L2X/)2 = (V^), -

Table 6.16 Properties at 550C

Component A,-, kJ/kinol Cmpi, kJ/(kmol • K) Cu, kJ/(kmol • K)

C3Hs 12 895.3 79.932 128.95
C^.o 19 183.9 105.58 148.13
C5HI2 23 513.1 150.29 173.33
C.H 14 28 805.2 155.09 201.64

^2 yi + vi y; LiX, +L3Xi
03 = ZCja'A,- + X C
mpA' + L LlA1
Process Engineering Channel

03 = (23.741 x 12 895.3 + 29.06 x 19 183.9 + 20.6 x 23 513.1 + 15.82 x 28 805.2)

125.166 + 101.425 80.357 + 51.297

+ x 79.932 x 10 + x 105.58 x 10

40.19 + 19.588 f 27.038 + 11.22)

+ x 150.29 x 10 + x 155.09 x 10
@ProcessEng

\
24.834 + 48.575 44.643 + 73.7028
+ , x 128.95 x 10 + x 148.13x10

\ /
59.81+80.4117 97.962 + 113.7812 j
+ x 173.33x 10 + x 201.64x10
/
03 = 1803 699.6 + 234 646.85 + 469 986 = 2508 332.5 kl/h = 696.76 kW
 208 Introduction to Process Engineering and Design

Fourth interval:

Table 6.17 Flash Calculation for Range 50oC to 40°C

Component VaYi Kj(=40»C) L x

3 i v
4yi C4<
CJHB 101.425 3.00 48.5751 85.714 64.286 37.14
C^.o 51.297 0.95 73.7028 101.01 23.990 27.31
c5h12 19.588 0.32 80.4117 92.593 7.407 12.18
C6H14 11.220 0.12 113.7812 121.36 3.640 7.58

Total 183.53 316.4708 400.677 99.323 84.21

Value of L^Xj, V^y, and C4x' of above table are obtained by following calculations.

L4 - I.L4xi = S

1+ ^/(=40oC)
L4

150 125 100 125

L4 = IL+Xj = + +■
V. V, K,
1 + —x3 1 + —x0.95 1 + —x0.32 1 + —x0.12
L,a La La La

V4
Trial: Assume — = 0.25
L4

L4 = 85.714 + 101.01 + 92.593 + 121.36 = 400.677 kmol/h

K,
V4 = 99.323, — = 0.248 = 0.25
L4
F
^43', = Zi - L4Xr C X
4 i= (L X
4 i)4 - (L3xih

( ^3 + Vj4 V; ' L3 Xj + L4 Xj
<P4 = SC4A-;A, + i ' ' C
mpi At + S c
u Ar

Table 6.18 Properties at 45°C

Component A,, kJ/kmol Cmpi, kJ/(kmol ■ K) Cu, kJ/(kmol • K)

Process Engineering Channel

C3H8 13 448.0 77.785 125.27

C4HI() 19 912.4 102.850 143.27
c5hi2 24 116.0 126.910 168.81
c6hI4 29 525.3 151.440 198.04

^3 y* + K y) L3 Xj + L4 Xj
@ProcessEng

(p4 = ZQa/A, + I Cmpfa ^ A ClA'

</»4 = (37.14 x 13 448 + 27.31 x 19 912.4+ 12.18x24 116 + 7.58 x29 525.3)

101.425 + 64.286
+ x 77.785 x 10
 Process Design of Heat Exchangers

51.297 + 23.99 f 19.588 + 7.407 ^

+ x 102.85 x 10 + x 126.91 x 10

/
11.22 +3.64 N 48.5751 +85.714
+ x 151.44 x 10 + x 125.27 x 10

/
73.7028 +101.0 r 80.4117 + 92.593
+ x 143.27 x 10 + x 168.81 x 10

113.7812 + 121.36
+ x 198.04 x 10

(/»4 = (156 0801 + 131 547.2 + 588 128.9) = 2280 477.1 kJ/h = 633.46 kW
Fifth (final) Interval:

Table 6.19 Flash Calculations for Range 40°C to 310C

£

+1

Component v L x
11

4yi Fw, 4 i Q*,

CjHg 64.286 0 85.714 64.286 150
CAo 23.990 0 101.010 23.990 125
c5hi2 7.407 0 92.593 7.407 100
C6H|4 3.640 0 121.360 3.640 125
Total 99.323 400.677 99.323 500

Table 6.20 Properties at 35.50C

Component A,-, kJ/kmol Cmpi, kJ/(kmol ■ K) Cu, kJ/(kmol ■ K)

CA 14 553.3 75.72 123.43

CjH.o 20 155.3 100.23 140.84
C5H,2 24 718.9 123.67 165.8
QHl4 30 245.4 147.22 194.4
Process Engineering Channel

F^.+O L4Xi+L,xi
05 = IC5x'/l, + Z cmpAt + z ClA*

05 =(64.286 x 14 553.3 + 23.99x20 155.3 + 7.407x24 718.9 + 3.64x30 245.4

64 286 23 99 7 407
+ I ——— x 75.72 x 11 + x 100.23 x 11 + l^LL x 123.67 x 11
2 2 2
+ 3:64 x i47_22 x 111
@ProcessEng

/
85.714 + 150A Moi.oi + ns^
+ x 123.43 x 11 + x 140.84 x 11

' 92.593 +100 A 121.36 + 125

+ x 165.8 x 11 + x 194.4 x 11
 Introduction to Process Engineering and Design

<p5 = 17 12285.2 + 47 806.1 + 77 4123.5 = 25 34214.8 kJ/h = 703.95 kW

Total heat duty 0, = 0, + 0, + 03 + 04 + 05
= 1070.1 + 716.1 + 696.76 + 633.46 + 703.95 = 3820.37 kW
Assume chilled water as a cooling medium.
Let inlet temperature of chilled water, /, = 60C
Outlet temperature of chilled water, t0 = 9°C
Energy balance:

5
0r = £0,. = 3820.37 kW = mw x 4.1868 x (9 - 6)

Mass flow rate of chilled water required

3820.37
mw = = 304.16 kg/s
4.1868x3

mw = 1094 976 kg/h = 1095 m3/h

(81-9)-(70-8.159)
AtaJLMTD) for 1st interval = 7———7— = 66.790C
81-9
In
70-8.159

Table 6.21 Summary of Heat Balance Calculations

Interval (Based on Temperatures Heat duty 0, kW Atavi, (LMTD)

vapour temperature) of chilled water

810C to 70oC 8.16X to 9X 1070.1 66.79X

70oC to 60oC 7.6X to 8.16X 716.1 56.99X
60oC to SOX 7.05X to 7.6X 696.76 47.52X
SOX to 40X 6.553X to 7.05X 633.46 38X
40X to 31X 6X to 6.553X 703.95 29.02X
Total 3820.37

Figure 6.21 gives the results in diagramatic form.

Process Engineering Channel

10,.
Weighted At = (6.48)
'Pi
At
avi

3820.37
Weighted At =
1070.1 + 716.1 + 696.76 + 633.46 + 703.95
@ProcessEng

66.79 56.99 47.52 38 29.02

0
Weighted At = 45.385 C
Heat duty 0, = 3820.37 kW
Heat duty for subcooling
 Process Design of Heat Exchangers

Chilled Hydrocarbon
water Vapours

/one 1 Zonc-2 Zone-3 I I Zonc-5

1070 k\V 0^ = 716.1 kW 0. - 696.76 kW 0s = 703.95 kW
'0°c ZONE-4 I
HC 04 = 633.46 kW
60 0C o
50 c
■lO'c 3l
Cooling Water °c I
9C
.16 C 7.60 C rm c 5°C
6.55 C

Chilled Condensate
Water
Fig. 6.21 Condenser for Condensation of Hydrocarbon Vapours

^sub = 143 602.7 + 331 589 + 469 986 + 588 128.9 + 774 123.5
= 2307 430.1 kJ/h = 640.95 kW
Heat duty for condensation
(
Pc = (P,- hub = 3820.37 - 640.95 = 3179.42 kW
This value includes heat load required for cooling of vapour. Heat transfer coefficient
for the cooling of vapour in presence of condensation is quite high. Also, cooling of
vapour and condensation of vapour both are taking place simultaneously. Hence, as per
the Kern's suggestion, separate calculation for determining heat transfer coefficient for
cooling of vapour is not required.
Assume values of overall coefficients for the first trial calculation.
Overall coefficient for condensation f/(X, = 800 W/(nr • 0C)
Overall coefficient for subcooling Uomb = 200 W/(m2 • 0C)
Provisional heat transfer area:

For condensation, A.nr = —

cpro
Uoc x weighted At

3179.42 xlO3 ,
A'cpro = = 87.568 m2
Process Engineering Channel

800x45.385

hub 640.95 xlO3

For subcooling, Asub pro = = 70.61 m2
Uosub x weighted At 200 x 45.386
Total heat transfer area Apr() = 87.568 + 70.61 = 158.18 m2
Let tube length L = 8 ft = 2.4384 m
Tube outside diameter = 3/4 in = 0.019 05 m
@ProcessEng

158.18
Number of tubes, N, =
ltd,, L tt x 2.4384 x 0.019 05

Nt= 1084
Let tube pitch P, = 1.25 d0 = 0.023 81 m, triangular pitch arrangement, number of tube
side passes = 4 (for first trial calculations)
 Introduction to Process Engineering and Design

Tube bundle diameter

"i
D
h = d0 (6.1)
V^ y
for Np = 4, ^ = 0.175, n, = 2.285 (Table 6.2)
i
285
r-. = 19.05
D mncf 1084 V- = o-7n
870 mm
b
10.175 7
Let the clearance between shell inside diameter and tube bundle diameter =16 mm.
Shell ID Ds = 870 + 16 = 886 mm
Tube side heat transfer coefficient hf.
Allocate chilled water on tube side

N, TT
Tube side flow area, a, = —— x —dj (6.20)
p ^
Tube inside diameter, = 15.748 mm (For 16 BWG tube)

a = x - (0.015 748)2 = 0.052 785 m2

4 4

Tube side mass velocity Gt = —= = 5762.24 kg/(m2 • s)

ar 0.052 785
Density of water at 7.50C, p = 999.877 kg/m3
(From Table 3.28 of Ref. 2)

G, 5762 24
Tube side velocity, u. = — = = 5.76 m/s (very high)
^ ' p 999.877 v ^ e /
Velocity of water in tubes should preferably be in between 1 to 3 m/s.
Let number of tube side passes = 1
for Np = 1, K{ = 0.319, n, = 2.142 (From Table 6.2)
i
142
r> mncl
Du = 19.05 1084 V = 848 mm
0.319,
Process Engineering Channel

Shell ID, Ds = 848 + 16 = 864 mm (Revised)

Tube side flow area, a, = x IL (0.015748)2 = 0.2111 m2

G = 304.16 = ,440 83 k /m2. s)

' 0.2111

1440 83
@ProcessEng

u, = — = = 1.44 m/s which is within acceptable range

' p 999.877

d.G,
Tube side Reynold's number. Re, =

Viscosity of water at 7.50C, p = 1.3 x 1()"3 kg/(m ■ s)

 Process Design of Heat Exchangers

0.015 748 x 1440.83

Re. = = 17 454
1.3x10"3

CPH
Prandtl number, Pr =
k
Thermal conductivity of water at 7.50C, k = 0.596 85 W/(m • 0C)

4.1868 x 1.3 x 10-3 x 103

Pr = =9.12
0.596 85
Dittus-Bolter equation
) j
kd: / " \014
0 ) 33
-—= 0.023 Re * /V - (6.19)
k \ Pw J
0.596 85 ns n„
h: = 0.023 x x (17 454) x (9.12)0-33 x 1
0.0157 48
/*, = 4473.85 W/(m2 • 0C)
h0: Heat transfer coefficients for both condensation and subcooling must be determined
separately.
For condensation hnc
For the first trial calculation let hoc = 1500 W/(m2 ■ 0C)

KdZ- %.) = U^- ^

where Uoc = 800 W/(m2 ■ 0C)

81 + 31
% = shell side average temperature = —^— = 560C

% - Tube wall temperature, 0C

6+9
Tt - Tube side average temperature = —-— = 7.50C

1500(56 - Tw) = 800(56 - 7.5)

% = 30.13oC
(
TS +Tll, 56 + 30.13
Mean temperature of condensate film, 'Tf = = ^

^=430C
Process Engineering Channel

Physical properties of liquid condensate should be determined for the average conden-
sate composition. Here, properties are determined based on the composition of conden-
sate in the intermediate (third) interval.

Table 6.22 Properties of Liquid Condensate in 3rd Interval

Component cy; Mole fraction Mass fraction pL, kg/m3 /+ cP k, W/(m ■ 0C)
@ProcessEng

C3HS 23.741 0.2660 0.1874 582 0.10 0.1211

c4HI0 29.060 0.3257 0.3024 579 0.15 0.1263
c5h12 20.600 0.2309 0.2661 626 0.20 0.1305
c6h14 15.820 0.1773 0.2441 659 0.27 0.1367

89.221 1.0000 1.0000

 Introduction to Process Engineering and Design

(For viscosity. Fig. 14 of Ref. 5)

1
Pl=i- 1/- = 609.84 kg/m3
0.1874 | 0.3024 | 0.2661 | 0.2441
582 579 626 659
Viscosity of liquid mixture by Irving's equation (Equation 3.107 of Ref. 2)
In nLmix = Iw, In /i, = [0.1874 In (0.1) + 0.3024 In (0.15) + 0.2661 In (0.2)
+ 0.2441 In (0.27)]
3
liLmix = 0.1732 cP = 0.1732 x lO" kg/(m • s)
k/ mix = Ucixi = 0.266 x 0.1211 + 0.3257 x 0.1263 + 0.2309 x 0.1305
+ 0.1773 x 0.1367
A:imix =0.1277 W/(m - K)
Average molar mass of vapour mixture,
Mav = lMjyi = 0.3 x 44 + 0.25 x 58 + 0.2 x 72 + 0.25 x 86 = 63.6 kg/kmol

pMav
Density of vapour mixture, pv =
RT

4x63.6 273
x = 9.418 kg/m3
(273 + 56) 1x22.414
Position of condenser: Horizontal
Shell side condensation coefficient
-,1/3
Pl(Pl-Pv)8 -1/6
hoc = 0-95 kL . Nr (6.37)

W€ , 2 2 f 848
Ti = -^-,N=2/3 N=- = -x = 24
LN, 3 Pt J 3 I 23.81

IV(. = (23.741 x 44 + 29.06 x 58 + 20.6 x 72 + 15.82 x 86)/36()0

iy(. = 1.548 kg/s

1.548
T,. = = 5.856 x lO"4 kg/(m ■ s)
(1084x2.4384)
Process Engineering Channel

1/3
609.84(609.84-9.418) x 9.81 -1/6
hoc = 0.95 x 0.1277 x (24)
3 -4
0.1732 x 10~ x 5.856 x 10

= 0.95 x 0.1277 x 32 839.57 x 0.5888 = 2345.7 W/(m2 ■ 0C)

For the second trial calculation if it is assumed hoc = 2345.7 W/(m2 • 0C) (resulting value
of first trial calculation) condensate film temperature, ^ = 47.730C (revised). Hence,
@ProcessEng

minor change in the value of film temperature is noted. Also, precise temperature wise
physical properties of these components (particularly density and thermal conductivity)
are not available. So, second trial calculation will not make any difference in the final
value.
hoc = 2345.7 W/(m2 • 0C)
 Process Design of Heat Exchangers 215

As stated earlier with horizontal position, subeooling of condensate is taking place by

natural convection only. No reliable correlation is available for natural convection. Hence,
based on Kern's recommendation, assume
hosub = 50 Btu/(h • ft2 • 0F) = 283.77 W/(m2 • 0C)
Overall Heat Transfer Coefficient for Condensation

1
U
oc = (6.42)
1 | 1 | (IJnidJd, ) | d,, 1 | dp i
n
hoc od di h, d, hid
For light hydrocarbon mixture hud = 5000 W/(m2 • 0C) (From Table 6.9)
For cooling water hid = 4000 W/(m2 • 0C)
Thermal conductivity of tube material
£,,, = 50 W/(m • 0C) (Steel or cupronickel tube)

19.05
0.019 05 In
1 1 15.7487 , 19.05 w 1
+ + i X"
Voc 2345.7 5000 2x50 15.748 4473.85

19.05 1
+ x
15.748 4000
Uoc = 809.47 W/(m2 • 0C)
Heat transfer area required for condensation

_ <Pc _ 3179.42 x 103

creq " U x weighted At " 809.47x45.385
oc

Ac,cq = 86.54 m2
Overall heat transfer coefficient for subeooling

1 djnidjd;) du d„
+ •+ + + (6.42)
U osub osub h.od 2 k... do h, d: h;id

/ N
19.05
0.019 05 In
I 1 15.748 19.05 1
■+ x
+ +
U osub 283.77 5000 2x50 15.748 4473.85
Process Engineering Channel

19.05 1
+ x
15.748 4000
= 2 0
(/osub 230.78 W/(m • C)

^sub 640.95 xlO3

^sub x
(/osub weighted A/ 230.78 x 45.385
@ProcessEng

2
'subreq = 61.19 m
Total heat transfer area required,
Areq = 86.54 + 61.19 = 147.73 m2
Total heat transfer area required,
Apro = 158.16 m2
 Introduction to Process Engineering and Design

% Excess heat transfer area = | - I ) x 100 = 7.06 %

1147.73 J
It is not above 10%.
If number of tubes is increased to 1200,
D/, = 889, shell ID = 905 mm, Nr = 1200

1200
a, x 0.2111 = 0.2337 m2
1084

G = 304.16 = 1301 5 k /(m2 . s)

' 0.2337

,30L5
Re = x 17 454 = 15 766.18
1440.83

^, 1301.5 i -mi/; /
u, = GJp = = 1.3016 m/s
999.877

0.8
15 766.18
h, = 4473.85 x
17 454

/i,. =4124.26 W/(m2 • 0C)

hToc oc N, , rr_"6
*4/3 ■ N

Nr = (2/3) N; = (2/3)^ = = 24.9 = 25

(1200 V/3 v ( 25 V"

6
_ 0/1. n w/, 2z 0
h0,. = 2345.7 x x — =2410 W/(m ■ C)
V10847 K24J
Uoc = 801.97 W/(m2 • 0C)
Heat transfer area required for condensation

(ft.
TC 3179.42 xlO3
A —
crcq
Uoc x weighted At 801.97 x 45.385

Acre, = 87.35 nr
Process Engineering Channel

Uosub = 229.57 W/(m2 • 0C) (based on new value of /*,)

640.95 xlO3 ,
Asubrea
subreq = x 45385 = 61-52 lir

Total area required, Alret| = 148.87 m 2

A^ pro = N^dJL = 1200 x ^-x 0.019 05 x 2.4384 m = 175.12 m2
@ProcessEng

% Excess heat transfer area = | -1 | x 100 = 17.63%

V 148.87 J
It is adequate.
If equal % excess heat transfer area for condensation and subcooling are provided then,
 Process Design of Heat Exchangers

Area provided for condensation Acpro = 1.1763 x Acrcq

A,pro = 102.75 m2
A sub pro = 175.12 - 102.75 = 72.37 m2

A"bl" 1231
=0.4133
A,pro 175.12

Thus, 41.33% of total heat transfer area is available for subcooling and the same area
should be submerged in the pool of condensate. Assuming that tubes will be uniformly
distributed in the crossesction of shell.

se rnent cross sec,: on

Aiubpro o 4133 ^ " j utilized for subcooling
A,pro Total cross-section area of shell

xDj
—— = 0.4133 orjc = 0.3246
—D2
4 '

(From Table 1.19 b of Ref. 2)

for x = 0.3246, — =0.432

D
i
To facilitate the subcooling of condensate or to submerge 41.33% of total heat transfer
area in the pool of condensate, height of inverted U-seal required from the bottom most
point of shell inside diameter.
h = 0.432 x 905 = 390.96 mm = 391 mm (as shown in Fig. 6.21)

6.7 PROCESS DESIGN OF REBOILERS AND VAPORIZERS

Design correlations for reboilers and vaporizers are same. Reboilers are used
with distillation columns. In a reboiler part of liquid fed is vaporized while in a
vaporizer the entired feed of liquid is vaporized.
Following types of Reboilers are used in chemical industries.
(a) Kettle type Reboiler
(b) Bundle-in-column Reboiler
Process Engineering Channel

(c) Horizontal Thermosyphon Reboiler

(d) Vertical Thermosyphon Reboiler
(e) Forced Circulation Reboiler.
Process designs of Kettle type Reboiler and Vertical Thermosyphon Reboiler
are given in subsequent sections.

6.7.1 Process Design of Kettle Type Reboiler

@ProcessEng

Kettle type reboiler (see Fig. 6.1(e)) is normally used with a distillation column
and also as vaporizer. Vapour leaving the kettle type reboiler is always in equilib-
rium with the liquid. In this type of reboiler heating surface is immersed in the
pool of liquid. Hence, perfect pool boiling is taking place. In pool boiling, maxi-
mum value of heat transfer coefficient is achieved in nucleate boiling region. To
achieve the nucleate boiling region, A V(Temperature difference between
 218 Introduction to Process Engineering and Design

temperature of heating surface and boiling temperature of liquid) should be less

than and close to critical temperature drop. Critical temperature drop for water is
20 to 30oC and for light organics is 20 to 50oC. In kettle type reboiler boiling
fluid side pressure drop is negligible, hence it is preferred with high vacuum
distillation column.

6.7.1.1 Process Design Steps

(a) Calculation of heat duty.

In actual design calculation, heal duty of reboiler is calculated based on
energy balance equation around distillation column.
= Hj) + HwW - HfF + (t>c+(l>L (6-53)
where, = Heat duly of reboiler, kW
Hd = Enthalpy of distillate, kJ/kmol
D = Molar flow rate of distillate, kmol/s
Hw = Enthalpy of residue, kJ/kmol
W = Molar flow rate of residue, kmol/s
Hf = Enthalpy of feed, kJ/kmol
F = Molar flow rate of feed, kmol/s
(j)c = Heat duty of condenser, kW
0L = Heat loss of distillation system, kW
If the vaporization rate of reboiler is given then heat duty can be deter-
mined by following equation.
(j)B = mvX x 1.05 (6.54)
mv = Vaporization rate, kg/s
(considering 5% heat loss to surrounding)
(b) Fix the value of mean temperature difference A^. It should be less than
and close to critical temperature drop. Average temperature of healing me-
dium th = ATm + tB
(c) Select the suitable heating medium.
(d) Based on energy balance, find the mass flow rate of heating medium. If the
temperature of heating medium required is less than 180oC, then saturated
steam can be selected as heating medium. In this case,
qB = ms?is (6.55)
Process Engineering Channel

where, = Latent heat of vaporization of steam, kJ/kg (to be obtained

from Steam Tables)
ms = Mass flow rate of steam required, kg/s
(e) To get the first estimate of heat transfer area, assume the value of overall
heat transfer coefficient (Table 6.7). Find the heat transfer area based on the
assumed value of U„O'
@ProcessEng

A = = N L
TI AT Vovided = t^ (6-43)

(f) Fix the value of tube outside diameter d0 and tube length. Find the number
of tubes Nr Decide the lube arrangement. In reboiler, normally 1 in
 Process Design of Heat Exchangers

(25.4 mm OD) tubes are used. Square pitch arrangement with U tube-bun-
dle is preferred. In kettle type reboiler, higher value of tube pitch {P, = 1.5
d0 to 2d0) is preferred to avoid the "vapour blanketting" inside the pool of
liquid and over the heat transfer surface. Close distance between tubes pro-
vides more resistance to the flow of vapour bubbles. Close distance be-
tween the tubes with higher vaporization rate per unit area may result in
vapour blanketting which reduces the overall heat transfer coefficient and
hence reduces heat duty of reboiler considerably. With kettle type reboiler
full baffles (% Baffle cut = 0) are used as extra space is available for the
flow of liquid. Nucleate boiling coefficient or any phase change coefficient
does not depend on type of baffle or baffle spacing. Here, baffles are pro-
vided only to reduce the vibration in tubes. Here, baffle spacing can be kept
equal to tube bundle diameter or even higher than that but within permissi-
ble limit, specified in TEMA standard.
(g) Calculate shell side boiling coefficient by Mostinski equation.

0.7 0.17 \1.2 / \io

0.69 _P_
h
o= h
nB — O-104 P.c 1.8 +4 + 10
A Pc Pc Pc

(6.56)
where, h0 = hllB = Shell side nucleate boiling heat transfer coefficient in
W/(m2 ■ 0C)

0,/!
= Heat flux of reboiler, W/nr
A
pc = Critical pressure of component or psuedo-critical pressure of
the mixture of components vaporized, bar
p = Operating pressure in reboiler, bar
This equation is reliable for single component boiling. For, a mixture,
actual coefficient is lesser than the same predicted by this equation.
(h) Calculate tube side heat transfer coefficient, hf.
If saturated steam is used as heating medium, then calculation for h, is not
required. Value of 6000 W/(m2 o
C) can be safely used. This value also
Process Engineering Channel

includes fouling resistance.

1 , 1
or h; = 6000 W/(m2 ■ 0C)
V hi ^
If hot oil is used as heating medium , then /i,- is calculated by forced convec-
tion correlation. Eq. (6.18) or (6.19) depending on the value of Reynolds
@ProcessEng

number.
(i) Calculate the overall heat transfer coefficient U0, by Eq. (6.42).
(j) Calculate the heat transfer area required using Eq. (6.43).
(k) Calculate % excess heat transfer area. It should be in between 10 to 20%. If
not, then change the number of tubes or tube length. Repeat the calcula-
tions until % excess area is in the desired range.
 Introduction to Process Engineering and Design

(1) Based on the final or last value of heat transfer area provided, calculate the
actual heat flux.

0/?
Actual heat flux =
^provided
(m) Actual heal flux < 0.7 (0 / A)c
where (0M)C is critical heat flux. Critical heat flux is the heat flux corre-
sponding to critical temperature drop. This condition must be satisfied.
Critical heat flux can be estimated by modified Zuber's equation4 which
can be written as

i P, K ,2x0.25
= Ku \ — (VgipL -Pv)Pv ) (6.57)
o /

where,

V
= Critical heat flux, W/nr
A
c
Kb = Constant
Kb = 0.44 for square pitch arrangement and 0.41 for triangular pitch
arrangement
P, = Tube pitch, mm
d0 = Tube outside diameter, mm
Nl = Total number of tubes in bundle
2, = Latent heat of vaporization, J/kg
pv = Vapour density, kg/nr''
cj = Liquid surface tension, N/m
P! = Liquid density kg/m
g = Acceleration due to gravity = 9.81 m/s2
(n) Find the shell inside diameter. Shell inside diameter of kettle type reboiler
should be greater of following two values.
(i) Shell ID = Liquid level + 0.15 to 0.25 m
Process Engineering Channel

Liquid level in kettle type reboiler = Tube bundle diameter + 50 to

100 mm
To find the tube bundle diameter for U tube bundle, Eq. (6.2) and for
tube bundle with floating head, Eq. (6.1), can be used.
(ii) Minimum Shell ID can be obtained from following table.

Table 6.23 Minimum Shell Diameter of Kettle Type Reboiler

@ProcessEng

Heat flux, W/m2 Shell ID/Tube bundle diameter

< 25 000 1.2 to 1.5

25 000 to 40 000 1.4 to 1.8
> 40 000 1.7 to 2.0
 Process Design of Heat Exchangers

(o) Check the liquid entrainment. To avoid the excessive entrainment, vapour
velocity at liquid surface should be less than vmax.

Nl/2
Pl - Pv
Vmov
max = 0.2 (6.58)

where, vmax = Maximum permissible vapour velocity at liquid surface, m/s

p, = Density of liquid phase kg/m3
p,, = Density of vapour phase kg/m
Actual vapour velocity at liquid surface.

mv/p,,
v= (6.59)
Liquid surface area

Liquid surface area = Lx x (6.60)

where, L = Tube length
x = width of liquid level

6.7.1.2 Boiling of Liquid Mixture

For the close boiling liquid mixture (boiling range is less than 50C), Eq. (6.56)
can be used to find the nucleate boiling coefficient. If for the given liquid mixture
boiling range is wide then, use of Eq. (6.56) is not recommended. For such a
mixure, Palen and Small equation can be used.

(Kb) mixture -f/?i x

(Kb) single component (6.61)

where, fm = exp f-0.0083 (^ - IfJ] (6.62)

0
^ = Temperature of vapour mixture leaving the reboiler, C
= Temperature of liquid entering the reboiler, 0C
Kettle type reboiler can be considered as one equilibrium stage. Hence, the vapour
leaving the reboiler is in equilibrium with the residue. Dew point temperature of
vapour leaving the reboiler (^0) is equal to bubble point temperature of residue.
To find 'J/jp (Bubble point temperature of liquid entering to the reboiler), composition
of liquid entering to reboiler must be determined. Material balance around reboiler
gives composition of liquid {xlj) entering to reboiler.
Process Engineering Channel

L = V + W (6.63)

Lxu = vyi + ^ xi (6-64)

where, W = Molar flow rate of Residue, kmol/s
Xj = Mole fraction of component i in residue
yi = Ki Xj = Mole fraction of component / in vapour leaving the reboiler
xu = Mole fraction of component / in liquid entering to reboiler.
@ProcessEng

V = Molar flow rate of vapour leaves the reboiler, kmol/s

L = Molar flow rate of liquid enters to reboiler, kmol/s
Bubble point of liquid entering to reboiler, gives the value of TBp.
 Introduction to Process Engineering and Design

Example 6.5
A packed distillation tower with overhead condenser and kettle type reboiler is used for
aromatics separation. Design conditions of the column are as follows.

Table 6.24 Composition of Distillation Column Streoms

Component Composition, mole %

Feed Distillate Bottoms
Benzene 2.2 22.8 0
Toulene 7.4 72.2 0.5
Ethyl benzene 43.4 5.0 47.5
Styrene 47.0 0 52.0

Feed flow rate to distillation tower is 100 kmol/h.

A reflux ratio of 6.0 is selected for the design. Operating pressure at the base of
column is fixed at 21.3 kPa a (160 torr). All the streams may be taken as saturated
liquids. Also assume that the mixtures are ideal mixtures. Saturated steam at 0.2 MPa a
pressure is used as heating medium in kettle type reboiler.
Design the kettle type reboiler for this distillation column.
Solution:
Heat duty of kettle type reboiler
0/; = + HdD + HwW - HyF + (p, (6.53)
To calculate the heat duty of reboiler 0g by using above equation flow rates (F, D and
W), latent heats at bubble point temperatures, specific heats of liquid streams, bubble
point temperatures of streams, dew point temperature of over head vapour, etc. must be
determined.
F = Feed flow rate = 100 kmol/h
F=D+ W
where D and W are molar flow rates of distillate and residue (bottom product).
D+W= 100
Benzene balance
0.228 D = 2.2
or D = 9.65 kmol/h
W = 100 - 9.65 = 90.35 kmol/h
Process Engineering Channel

(/»c = Heat duty of condenser = (R + 1) DA.

R = 6, D = 9.65 kmol/h
Latent heat of vaporization must be determined at the average temperature of the dew
point and bubble point of distillate product. Assuming negligible pressure drop in the
tower, operating pressure is constant throughout the distillation column and is equal to
operating pressure at the base of column for heat duty calculation, i.e. 21.3 kPa a.
Assumption of constant pressure throughout the column is not true in real case but for
@ProcessEng

simplicity this assumption is made. In actual case, top pressure is to be found by distilla-
tion calculations and dew point at the real pressure at the top is to be calculated.
Bubble point of Distillate
For ideal vapour liquid equilibrium,
at bubble point Zx, pfdl = p, and z, = x,-.
Vapour Pressure Data:
 Process Design of Heat Exchangers 223

Table 6.25 Antoine Constants9

Component A B C
Benzene 6.0306 1211.0 -52.35
Toluene 6.0795 1344.8 -53.65
Ethyl benzene 6.0821 1424.3 -59.95
Styrene 6.1911 1507.4 -58.15

Antoine equation logl0 pv = A - —

1 "t* C
where pv is in kPa and T is in K.
At bubble point of distillate,
0.228 pvB + 0.722 pvT + 0.05 pvEB = p,
Trial 7= 328.3 K
At 7" = 328.3 KpvB = 43.865 kPa, pvT= 15.244 kPa andpvFB = 5.95 kPa
0.228 x 43.865 + 0.722 x 15.244 + 0.05 x 5.95 = 21.3 kPa = p, (Check!)
0
Bubble point of distillatem = 328.3 K (55.3 C)
At dew point of distillate

^ P,
= 1 and Zj = y,-
pf
Try T = 334.7 K
pvB = 55.1565 kPa, pvT = 19.7054 kPa, pvEB = 7.909 kPa

Dew point temperature of distillate. TDP = 334.7 K (61.70C)

Latent heat of vaporization must be determined at average temperature.

328.3 + 334.7
rav. = = 331.5 K

Table 6.26 Properties of Components of Distillate

Process Engineering Channel

Component y,- Critical temperature 7), A" A at T,, kJ/kmol

7V°K
Benzene 0.228 562.16 353.3 30 761
Toluene 0.722 591.79 383.7 33 179
Ethyl benzene 0.05 617.2 409.3 35 564

0.38
Tc-T
@ProcessEng

^■2
(Watson equation)
A, Tc-Ti
For Benzene
0.38
An 562.16-331.5
30761 562.16-353.3
As = 31 943.68 kJ/kmol at 331.5 K
 Introduction to Process Engineering and Design

Similarly,
lr = 36 124.5 kJ/kmol at 331.5 K
XFli = 40 130.243 kJ/kmol at 331.5 K

K\ - ^vi )'/
= 0.228 x 31 943.68 + 0.722 x 36 124.5 + 0.05 x 40 130.243
= 35 371.56 kJ/kmol
Heat duty of condenstion
</», = (/?+ 1 )D Aav
0c = (6 + 1) x 9.65 x 35 371.56 = 238 9348.9 kJ/h = 663.7 kW
Let 331.5 K be the reference temperature for enthalpy calculations, i.e. 7^ = 331.5 K
HD=0,HDD = 0
HwW
Residue is bottom product of Distillation and is a saturated liquid or at its bubble
point. To find the enthalpy of residue, first the bubble point of residue must be deter-
mined.
At bubble point of liquid Zx(- /?(sat = pl and Zj = x(-

x-
Trial; At 7= 363.55 K or ^ ^= 1
P,
Vapour pressures, pvT = 54.959 kPa, pvFB = 24.588 kPa
pvS = 18 Pka, p, = 21.3 kPa

Table 6.27 Bubble Point Calculations for Residue

Component x,- pvi

ii

Toluene 0.005 54.959 0.013

Ethyl benzene 0.475 24.588 0.548
Styrene 0.52 18 0.439
Zy,- = 1 (check)

Bubble point of residue TBP = 363.55 K (90.55oC)

Empirical heat capacity equation for liquids
Cml =a + bT+ cT2 + dT3
Process Engineering Channel

where Cml is in kJ / (kmol ■ K) and 7is in K

Table 6.28 Heat Capacity Equation Constants

Component a bx 103 ex 106 dx I09

Toluene 1.8083 812.223 -1512.67 1630.01

@ProcessEng

Ethyl benzene 4.3143 900.174 -1450.05 1433.6

Styrene -38.019 1197.21 -2195.65 1933.12
Benzene -7.2733 770.541 -1648.18 1897.94
 Process Design of Heat Exchangers 225

Table 6.29 Heat Capacity Equation Constants for Residue

Component x
i O, X xi hi x Xi x 103 Cj x Xj x I06 dj xXjX 109

Toluene 0.005 0.009 4.061 -7.563 8.15

Ethyl benzene 0.475 2.049 427.583 -688.774 680.96
Styrene 0.52 -19.77 622.549 -1141.738 1005.222
Total 1.00 -17.712 1054.193 -1838.075 1694.332

Enthalpy of residue,
r r
jr2 'T'2 ^4 ^4
1
*0 ir'2> 'T'3
l0 1
Hw = lafC; x(T-Ta) + I hrxi x + X Cj xi X + X d: X: X

where, T0 = reference temperature = 331.5 K

363.552 - 331.52
// =-17.712(363.55-331.5)+ 1054.193 x 10,-3 - 1838.075 x 10-6

363.553 - 331.53 9
363.554 -33I.54
x + 1694.332 x 10- x
4
H... = 6338.32 kJ/kmol
HwW = 6338.32 x 90.35 = 572 667.2 kJ/h = 159.074 kW
HFF:

Table 6.30 Heat Capacity Equation Constants for Feed

Component Xi a, x Xj hj x Xj x 103 CjXXjX I06 djXjX 109

Benzene 0.022 -0.16 16.952 -36.26 41.755

Toluene 0.074 0.134 60.105 -111.93 120.621
Ethyl benzene 0.434 1.872 390.676 -629.322 622.182
Styrene 0.47 -17.869 562.689 -1031.956 908.566
Total 1.00 -16.023 1030.422 -1809.476 1693.124

yZ yZ
Process Engineering Channel

1 l
3 h o
HF = -16.023(7; - T0) + 1030.42 x lO"

■p4 -t-4
6 Th T" 1
' 9
'o
- 1809.476 x J O" + 1693.124 x lO" 1 —

where, TBP = bubble point of feed, T0 = reference temperature

@ProcessEng

At bubble point X ' = Sy,- = 1

Pt
Trial: At 7= 357.75 K, p, = 21.3 kPa
 Introduction to Process Engineering and Design

Table 6.31 Bubble Point Calculation

^ Pv
Component x
i Pvr kPa

P,
Benzene 0.022 116.227 0.12
Toluene 0.074 45.422 0.158
Ethyl benzene 0.434 19.923 0.406
Styrene 0.47 14.445 0.319
1.00 1.003 (check)

Bubble point of feed, TBP = 357.75 K (84.75 0C)

357.752 -331.52
Hp = -16.023(357.75 - 331.5) + 1030.422 x 10i-3 - 1809.476

357.753 - 331.53 357.754 -331.54

x 10i-6 + 1693.124 x K)"9 = 5079 kJ/kmol

HpF = 507 900 kJ/h = 141.08 kW

Heat duty of kettle type reboiler
<pls = <pc + H^D + HwW - HpF + tp, (6.53)
(ps = 663.7 + 0 + 159.074 - 141.08 + <pL
(pB = 681.7 + (pL = 681.7 x 1.05 = 716 kW (considering 5 % heat loss)
In continuous operation at steady state, boiling temperature of liquid in kettle type
reboiler = Bubble point temperature of residue = Dew point temperature of vapour leav-
ing the reboiler = Steady state equilibrium temperature of kettle type reboiler = T/ip-
TBP = 363.55 K (90.55oC)
Critical temperature drop of light organics is ranging from 20oC to 50oC. For the precise
calculations, value of critical temperature drop and critical heat flux at the actual operat-
ing condition must be determined by experiment.
Temperature of heating medium 2^ = TBp + A'.T
should be close to and less than A-^.
A'4 = 30oC
Process Engineering Channel

Let
% = Temperature of saturated steam = 393.38 K = 120.23oC
A'4 = 393.38 - 363.55 = 29.830C
Saturated steam pressure = 0.2 MPa
Latent heat, Xi = 2201.6 kJ/kg (Ref: Steam Tables)
Steam required
@ProcessEng

716
= 0.325 218 kg/s= 1170 kg/h
IT 2201. 6

For the first trial calculatios, assume U0 = 1000 W/(m2 • 0C)

Heat transfer area based on assumed value of U„:
 Process Design of Heat Exchangers

05 716 x IQ3
A = = 24 m2 = A o provided
U
o ATm 1000x29.836

A0 providcd =24 m2 - N, K dn L
Nominal U tube length = 3.6576 m (12 ft)
d0 = 25.4 mm, di = 21.1836 mm (14 BWG)

A, provided = 24 m2 = W, x (0.0254) x 3.6576

Number of tubes = 82 ((/ tubes)
Number of tube holes in tube sheet = 82 x 2 = 164
Use square pitch arrangement.
Tube pitch P, = 1.5 d0 = 38.1 mm
Minimum U bend radius = 1.5 d0 = 38.1 mm
ho - hnBo = Nucleate boiling heat transfer coefficient for mixture = fm ■ hnB (6.61)
where, hnB can be determined by Mostinski equation2

0.7 0.17 / Nl.2 ,10

p
1.8 — +4 + 101 — (6.56)
yPc y

716x10 3
= 29 833.33 W/m2
A 24
P = 21.3 kPa = 0.213 bar
pc = Critical pressure of boiling liquid mixture, bar
No reliable method is available for estimating critical pressure of a mixture.
Pern =1 yiPa
fm = correction factor

Table 6.32 Composition in Reboiler

Component Residue composition Composition of vapour Composition of

liquid entering
reboiler
Process Engineering Channel

■*< WXj, kmol/h yi=pvixilpl Uy., kmol/h Lx,-, kmol/h

Toluene 0.005 0.45175 0.013 0.856 1.30775 0.0084

Ethyl benzene 0.475 42.9163 0.548 36.07 78.9863 0.5058
Styrene 0.52 46.982 0.439 28.895 75.877 0.4859
Total 1.00 90.35 1.00 65.82 156.17 1.000
@ProcessEng

Total material balance around reboiler

L = V +W
and component balance: Lxl( = Wx, + Vy,
 Introduction to Process Engineering and Design

where
V = Molar flow rate of vapour leaving the reboiler, kmol/h
L = Molar flow rate of liquid leaving the bottom most equilibrium statge, kmol/h
xu = Mole fraction of component i in L
Correction factor
fn = exp[-0.0083(^o - %ij\ (6.62)
where, 'Tbo = Temperature of vapour mixture leaving the reboiler , 0C
Tdp = Dew point temperature of vapour leaving the reboiler ,0C
or Tgp = Bubble point temperature of residue,0C
Tfo = Temperature of liquid entering to the reboiler = Bubble point temperature
of liquid entering the reboiler.
%0 = 90.4oC (363.55 K)
At Tbi

Z^=l
P,
To find L andx,, by Equations 6.63 and 6.64, value of V is required

v = ^
A,
A,..

Table 6.33 Properties of Residue Components

Component x
i Critical Temperature 7), K A.,-, kJ/kmol
Tc, K

Toluene 0.005 591.79 383.7 33 179

Ethyl benzene 0.475 617.2 409.3 35 564
Styrene 0.52 647 418.2 36 819
Total 1.00

-,0.38
Tc-T
A
A, Tc-Ti
Process Engineering Channel

To be precise, A must be determined at average temperature of Tbo and Tbi and also for
average composition of liquid. Here. Aav is determined at Tbo and for the residue compo-
sition as there is a negligible change in temperature and composition.
At T = Tho = 363.55 K
lr = 34 365 kJ/kmol, XEB = 38 356 kJ/kmol, As = 39 941 kJ/kmol
Aav = 0.005 x 34 365 + 0.475 x 38 356 + 0.52 x 39 941
Aav = 39 160 kJ/kmol
@ProcessEng

- 716 3600 .co,,,

V = x = 65.82 kmol/h
39160 1
L = V + W= 65.82 + 90.35 = 156.17 kmol/h.
Values of xu are calculated by using Eqs (6.63) and (6.64) and are given in Table 6.33.
 Process Design of Heat Exchangers 229

At = 363.1 K (Trial)
pvT = 54.1658 kPa, pvEB = 24.1972 kPa, pvS =17.7 kPa
/?, = 21.3 kPa

^X\iPvt 0.0084x54.1658 0.5058x24.1972 0.4859x17.7

X — 1 i
p, 21.3 21.3 21.3

X
\i Pv,
= 1 (check)
Pi
7;,. = 363.1 K
Correction factor fm = exp[-0.0083(363.55 - 363.1)]
fm = 0.996 27
h
o = hnBwix =fn " Kb = 0-996 27 X h
nB
Pcm = ^Pay-,

Table 6.34 Critical Pressure Data

Component pc, bar yi

Toluene 41.1 0.013
Ethyl benzene 36.1 0.548
Styrene 39.9 0.439
Total 1.00

pcm = I p^i = 0.013 x 41.1 + 0.548 x 36.1 + 0.439 x 39.9

= 37.83 bar, = 0.005 63

Pan 37.83
0 69 a7 17 0
hlnB
nB = 0.104 x (37.83) - x (29 833.33) [1.8P°„ + AP^ + IOP' J
hnB = 1304.72 W/(m2 ■ 0C)

h0 = = 0.996 27 x 1304.72 = 1299.85 W/(m2 • 0C)

For the condensation of saturated steam

/?,' = 6000 W/(nr ■ 0C)
Process Engineering Channel

This value also includes fouling resistance.

Overall heat transfer coefficient U0

1
i +^+rf>(^)+^x^ (642)
U0 K hod 2kw di h'
Shell side fouling coefficient, hod = 5000 W/(m2 ■ 0C)
Thermal conductivity of steel tube material, kw = 50 W/(m ■ 0C)
@ProcessEng

\
25.4
0.0254 In
1 l V21.1836 25.4 1
+ + + X
U0 1299.85 5000 2x50 21.1836 6000

Un = 822.86 W/(m2 ■ 0C)

 Introduction to Process Engineering and Design

Heat transfer area required

716 x l(r
= 29.17 m2
A ,
" (/„ Ar. 822.86x 29.83
Heat transfer area provided, Aopro = 24 m2
A "> ,4
oreq opro
Increase in heat transfer area will decrease the value of hnB and the value of U0. Value of
overall coefficient removed ({/0 = 822.86 W/(m2' 0C)) is within normal range (See
Table 6.7). Further decrease in the value of U0 is not required. To decrease the value of
Aorcq increase the pressure and temperature of saturated steam. Let saturation tempera-
ture = 404.35 K.
Pressure = 0.28 MPa
A, = 2170.1 kJ/kg

Steam required ms = —
A,

716
m
s= = 0.33 kg/s = 1188 kg/h
2170.1
A-T, = 404.35 - 363.55 = 40.8oC

716 xlO3
'^req = 21.327 m2
U,, AT.. 822.86x40.8

24
Excess heat transfer area = I —— 1 x 100
V 21.327
Excess heat transfer area = 12.533%

Actual heat flux, = 29 833.33 W/m2 < 0.7 1

A opro A
\n/c
This condition must be satisfied. To verify this condition critical heat flux is determined
by modified Zuber's equation.

/ \
P, A
Process Engineering Channel

(Gg (Pl " Pv)Pv )0'25

II

(6-57)
1

\A/
O

[p.
Kh = 0.44, p, = 38.1 mm, d0 = 25.4 mm
V, = 82x2= 164, g = 9.81 m/s2
A = Latent heat of vaporization, J/kg
Av = 39 160 kJ/kmol
Average molar mass of residue
@ProcessEng

Mav = IM, xi = 0.005 x MT + 0.475 x MEB + 0.52 x Ms

Molar mass of toluene MT = 92.141
Molar mass of ethyl benzene MFB = 106.168
Molar mass of styrene Ms = 104.152
Mav = 0.005 x 92.141+ 0.475 x 106.168 + 0.52 x 104.152 = 105.05 kg/kmol
 Process Design of Heat Exchangers

39160
X= x 103
105.05
X = 372 774.9 J/kg

PM* T,
Pv = (s = standard conditions)
X
RT T PSVS

Average molar mass of vapour

Mav = IMtfi = 0.013 x Mr + 0.548 x M£B + 0.439 x M5

Mav = 0.013 x 92.141 + 0.548 x 106.168 + 0.439 x 104.152 = 105.1 kg/kmol

21.3x105.1 273
Pv= x
363.55 101.325x22.414
3
pv = 0.74 kg/m
1
pL = Density of liquid mixture =
W:

Pu
For Residue

Table 6.35 Properties of Residue Components

Component w, (mass fraction) Pu, Liquid density, kg/m

X M
i i
W; —
Lx, Mi

Toluene 0.005 0.0044 867

Ethyl benzene 0.475 0.48 867
Styrene 0.52 0.5156 906
Total 1.00 1.00

0.0044 | 0.48 | 0.5156

867 867 906
Process Engineering Channel

3
pL = 886.68 kg/m
ct = surface tension of liquid mixture = om
Surface tension of liquid mixture can be estimated by following equation.

a'P = (Eq. 3.152 of Ref. 2)

where, am = Surface tension of liquid mixture, dyn/cm
[tf] = Parachor of component i can be obtained from Table 3.343 of Ref. 2
@ProcessEng

pLm = Liquid mixture density, mol /cm3

pVm = Vapour mixture density, mol/cm3
[%] for toluene = 189.6 (For C6 H5 - group) + 55.5 (For—CHj group).
=
[ toluene] 245.1
 Introduction to Process Engineering and Design

\(PEB\ = 189.6 + 55.5 + 40 (For —CH2— group)

= 285.1
189 6
[^siyreJ = - + (15.5 + 9) + 40 = 254.1

ooc. -ic.i/3
p0„ = 886.68 kg/m^ = 886.68 = 8.44
„ .. kmol
105.05 nr

103 1
= 8.44 x x
I 106
= 8.44 x lO- mol/cm3
3

pVm = 0.74 kg/m3 = x lO"3 = 7.041 x lO"6 mol/cm3

105.1

,71/4 = (T,1,;4 = 245.1 (8.44 x IO"3 x 0.005 - 7.041 x IO"6 x 0.013)

+ 285.1(8.44 x lO"3 x 0.475 - 7.041 x lO"6 x 0.548)
+ 254.1(8.44 x lO"3 x 0.52- 7.041 x lO"6 x 0.439) = 2.2666
c = 26.3936 dyn/cm

CT = 26.3936 x 102x
10
a = 26.3936 x K)"3 N/m

38. n 372 774.9

= 0.44 x x x (26.3936 x IQ-3 x 9.81 x (886.68 - 0.74)
25.4 VT64
x 0.74 2\0.25
)

0
= 64 317 W/m2

0.7 = 45 022 W/m2

(p (t>
Actual heat flux, — =29 833.33 W/m2 < 0.7
A

To find the tube bundle diameter for square pitch arrangement with U tube bundle,
Process Engineering Channel

following equation can be written.

^ D
i~i-
2 —
=NIPI2 + Area of central portion
4

^D2 s Nr P2 + Dh x Pt (for P, = 38.1 mm (1.5 in) = minimum U tube radius)

@ProcessEng

E Dl-DbP.-Nrf
r»2 =0
4

Pt±^P2 +A(nlA)N,P2
Db =
n
 Process Design of Heat Exchangers 233

V+jpf+nN^,2
Dh =
{nil)
Minor correction in this equation:

Pr+J P2 + KN, P2
Db = + d.
nil

38.1 + + ^xl64x38.12
Db = + 25.4 (82 Utubes = 2 x 82 = 164 tubes)
nil

Dh = 600.74 = 600 mm
Ideally tube bundle diameter must be determined based on actual tube sheet layout as
shown in Fig. 6.22.

tr o
o
o O \j_L Tie Rod
11 (-2)

oo\1515
/^—n \ P, = 38.II mm
>< \ IS d" = 25Amm
Qxxxxxx XX XXXX *

Fig. 6.22 Tube Sheet Layout Drawing for Db = 600 mm, Nt = 162

Let the height of weir which maintains the liquid level in kettle type reboiler be 700 mm.
Shell ID, Ds:
Ds = 700 + 250 = 950 mm
(where 250 mm is the vertical distance between shell ID and liquid level.)
or Ds = 1.6 D/, (From Table 6.23)
Hence, Ds = 960 mm
Based on Tube sheet layout drawing for Db = 600 mm, (V, = 162
Let shell ID, Ds = 960 mm (greater of two values )

Liquid Level
Process Engineering Channel

/ \
100 mm
mm
\

1
s
960

£
0
0
vO
@ProcessEng

-<

Fig. 6.23 Checking of Liquid Entrainment

 Introduction to Process Engineering and Design

Checking of liquid entrainment

To avoid the excessive liquid entrainment
V <
''max
where, v = Actual vapour velocity at liquid surface, m/s
v =
max Maximum permissible vapour velocity at liquid surface, m/s

(mv /p.,)
v=
L'x
where, L'x = Liquid surface area

L' = Tube length = (U tube)

L' = 1.8288 m
From geometry, width of liquid surface.

Liquid level - — = 220

960
-2202

x = 853.23 mm
Liquid surface area, L'x= 1.8288 x 0.853
= 1.5604 m2

(V x Average molar mass of vapour)/pv

v=
1.5604

(65.82x105.l)/0.74 i
X
1.5604 3600
v = 1.664 m/s
1/2
Pl - Pv
Vmax = 0-2 (6.54)
Pv

,1/2
886.68-0.74
Process Engineering Channel

v
max = 0-2 = 6.92 m/s
0.74

v < vmax => There is no excessive liquid entrainment.

Shell side or boiling side pressure drop Aps in case of kettle type reboiler is negligible.

Tube Side Pressure Drop Ap,

On tube side, condensation of saturated steam is taking place.
@ProcessEng

—m
_ I PK
oc
■A-
^ |i

AP, = 0.5 AP,' = 0.5 Np + 2.5 (6.28)

\Pw J
y
 Process Design of Heat Exchangers

3-6576
Here Np = 2, L = = 1.8288 m

4=0.021 1836 m
p = Density of saturated steam at 0.28 MPa

_ I 1
= 1.548 kg/m3
Specific volume of vapour 0.646 04

Tube side mass velocity, Gt =

x-df
N„ 4 '

0.33
Gt = = 11.56 kg/(m2 ■ s)
^p-jx ^-(0.021 1836)2

Tube side Reynolds number

d/Gt 0.021 1836x11.56

Re =
1-8
^ 1350x10"

Viscosity of saturated steam at 404.35 K

pr = 1350 x lO"7 poise = 1350 x lO"8 kg/(m • s))
Re = 18 139.44
7^ = 0.0041 (From Fig. 6.13)

1.8288 |1.548x7.4682
Ap, = 0.5x2 8x0.0041 xl+ 2.5
v 0.021 1836

G, 11.56
u
i = = 7.468 m/s
v p
' 1.548 y
Ap, = 230.15 Pa = 0.23 kPa (acceptable)

6.7.2 Design of Vertical Thermosyphon Reboiler

Process Engineering Channel

As a vertical thermosyphon reboiler, BEM type fixed tube sheet heat exchanger
is normally used. It is installed in the perfect vertical position. Figure 6.24 shows
standard location of vertical thermosyphon reboiler in which normal level of liq-
uid in distillation column is same as level of top tube sheet of heat exchanger.
Inside the lubes liquid is partially vaporized by using the healing medium like
saturated steam or hot oil on shell side. It decreases the density of fluid (vapour -
liquid mixture) in "hot" leg compared to the density of saturated liquid in rela-
@ProcessEng

tively "cold" leg and starts natural fluid circulation in the anticlockwise direction
as shown in Fig. 6.24 by arrows. In this type of reboiler, syphoning effect is
created by heating (thermally), hence it is called thermosyphon reboiler.
HTRI and HTFS have developed their own methods for the process design of
thermosyphon reboiler which are not available in open literature. The oldest and
 Introduction to Process Engineering and Design

Hot
leg

/
Steam

i-H
JD
"5
X3
(U
T
Residue

Cold leg
Condensate

Fig. 6.24 Standard Arrangement of Vertical Thermosyphon Reboiler

the simplest method for the process design of vertical thermosyphon reboiler is
Kern's method, which is outlined as follows.
(i) Calculate the heat duty of reboiler based on energy balance equation for
distillation column.
0b = 0c + Hd D + HwW - HfF + (t)L (6.53)
If vaporization rate is given then heat duty can be determined by Eq. (6.54).
0/j = mv/L x 1.05 (6.54)
(ii) Fix the value of mean temperature difference, A1fn. It should be less than
and close to critical temperature drop. Then, average temperature of heating
medium ^ = A'Tm+ 'Ify
(iii) Select the suitable heating medium. Based on the energy balance, find the
mass flow rate of heating medium required.
(iv) Assume the value of overall heat transfer coefficient, U0 = 1000 W/(m2 • 0C).
Find the heat transfer area based on assumed value of U0.

0R
A
o= = V = AW (6-43)
o^ w
Find or decide the required dimension of the heat exchanger.
(v) Assume the recirculation ratio equal to 4 for the first trial.
Process Engineering Channel

Mass flow rate of liquid recirculated

Recirculation ratio =
Vaporization rate

m
Lo
or Recirculation ratio = (6.65)
m,.
*VO
where, = Mass flow rate of liquid at outlet of reboiler
@ProcessEng

mvo = Mass flow rate of vapour at outlet of reboiler.

(vi) Do the pressure balance. At steady state,
Available differential head = Pressure loss in the circuit
or A pav = Pressure loss in the base of distillation column
+ Pressure loss in associated piping and nozzles
+ Pressure loss in reboiler (i.e. tube side pressure drop)
 Process Design of Heat Exchangers

Velocity of liquid through the shell of distillation column is very low

compared to the velocity of liquid through pipes. Hence, pressure loss in
the base of distillation column may be neglected. If piping arrangement is
smooth and higher sizing for the pipes is provided, then pressure loss in
piping may also be neglected. Hence, A/?av = A/?, at steadystate. Ap, = Tube
side pressure drop (loss) of reboiler. Available differential head, Apav is
calculated by following equation.
Apav =L(Pl- Pav) g (6-66)
where, Apav = Available differential head. Pa
L = Length of tube, m
-j
pL = Density of liquid in cold leg, kg/nr
3
pav = Average density of liquid vapour mixture in hot leg, kg/m
g = Acceleration of gravity = 9.81 m/s

ln(V0A/)
(6 67
v v - '
O I
where, V, = Specific volume of saturated liquid at the inlet of reboiler,
m3/kg
V, = l/pL
V0 = Specific volume of liquid vapour mixture at the outlet of
reboiler, mVkg

^ =
(m
— /p.,) + (m,to /p,)
HI. (6 68)

( mvo + m
u, )

where, mvo, mLo = Mass flow rates of vapour phase and liquid phase at
the outlet of reboiler, kg/s
In Kern's method, it is suggested to find Ap, by same equation that is
used for no phase change in the tube side fluid [Eq. (6.27)1. In this equa-
tion, p = pav = average density of tube side fluid.
(vii) Compare the value of available differential head Apav and pressure drop in
the system or tube side pressure drop, (Ap,), obtained based on assumed
value of recirculation ratio. There are total five possibilities.
Process Engineering Channel

(a) Apav = Ap,

(b) Apav > Ap,
(c) Apav > > Ap,
(d) Apav < Ap,
(e) Apav < < Ap,
(a) Apav = Ap, implies that the assumed value of recirculation ratio (4 for
1st trial calculation) is equal to the actual value of recirculation ratio.
@ProcessEng

Proceed for the next step of calculation.

(b) Apav > Ap,, implies that the assumed value of recirculation ratio is less
than the actual recirculation ratio. Hence, assume the higher value of
recirculation ratio, repeat the calculations and again compare the new
values of Apav and Ap,. By trial and error calculations, finally one can
find the recirculation ratio for which Apav s Ap,. Recirculation ratio
can have a fractional value.
 Introduction to Process Engineering and Design

(c) A/?av > > Ap, or Apav/Apt > 50 implies that the assumed value of
recirculation ratio is very much less than actual recirculation ratio. In
this case also, one can find the value of recirculation ratio for which
Apav = Apr by trial and error calculations but very high recircuation
ratio and hence very high tube side pressure drop may be obtained
which cannot be permitted. Very high tube side pressure drop will re-
sult in significant boiling point elevation inside the tubes of the reboiler
and decrease the mean temperature difference. Very high tube side ve-
locity gives erosion and vibrations in lubes. Hence, in such a case one
of the following options can be considered.
(i) Provide the control valve with flow meter in the inlet line to the
reboiler. Then, pressure balance is Apay = Ap, + Pressure loss in
flow meter + Pressure drop offered by control valve.
Pressure drop of control valve can be adjusted to the desired value.
This option also provides flexibility in the actual operation. In ac-
tual plant operation, recirculation ratio or circulation rate can be
corrected depending on the actual performance. This facility is not
available with other options.
(ii) Elevate the level of top tube
sheet of reboiler above the liquid
level at the base of distillation
column as shown in Fig. 6.25. fc-
In this option, A/?av = L' {pL - "o L
' -O
pav)g. Hence, this modification J a:
Residue
decreases the value of available
differential head Ap.dV and may "y
equate it with Ap, at the lower
value or reasonable value of
recirculation ratio. Fig. 6.25 Increase of Elevation of
(d) If Apay < Ap,, then one of the fol- Reboiler
lowing option can be considered.
(i) Increase the number of tubes and decrease the tube length. This modi-
fication will decrease the values of both Apay and Ap,. But, the per-
centage decrease in the value of Ap, will be more compared to the
Process Engineering Channel

same in the value of Apay. Hence, it may be possible to equate Apav

and A/?, for the lower value of recirculation rate.
(ii) A/7av < Ap,, implies that the actual recirculation ratio is less than
assumed or minimum recommended value of recirculation ratio. In
this case actual recirculation ratio can be increased by elevating liq-
uid level at the base of the distillation column above the top tube
sheet of reboiler as shown in Fig. 6.26.
@ProcessEng

In this case equation of Apav is changed.

A
Pav = P8h + L(Pl- Pav)£
But this modification may increase the height of skirt support of distil-
lation column. If increase in the height of skirt support is not possible,
then one can go for underground construction. If none of these options
 Process Design of Heat Exchangers

is permitted, then use pump in the

inlet line to the reboiler to increases
the circulation rate. Then this
reboiler is called a forced circulation
h
reboiler. T
Residue
(e) Ap.n, < < Ap, implies that the actual I
recirculation ratio is very low or very
much less than minimum recom- o L
0)
mended value, i.e. 4. This is possi- CC
ble when the viscosity of bottom 4

product of distillation column is very

high. In this case use a pump in the
Fig. 6.26 Decrease of Elevation of
inlet line to the reboiler to get the
Reboiler
desired value of circulation rate and
desirable value of tube side heat transfer coefficient. But then this
reboiler becomes a forced circulation reboiler.
(viii) After finding the recirculation ratio for which available differential head
becomes nearly equal to pressure loss in the system, calculate the tube side
heat transfer coefficient. In the latest method tube length is divided in dif-
ferent sections. For the different sections, different regimes of two phase
flow are considered. Hence for the different sections different values of
heat transfer coefficients are calculated by different correlations (Ref. 10,
11 & 12). But in the simplified Kern's method, it is suggested to use the
same forced convection correlation which are actually derived for the sen-
sible heat transfer (cooling or heating) of lube side fluid. Hence, in Kern's
method, h, is determined by Eq. (6.18) or (6.19). In addition to that Kern
has specified the maximum limit for the value of /t, as under.
If ^ > 300 Btu/(h • ft2 • 0F) [= 1700 W/(m2 ■ 0C)]
take ^ 1700 W/(m2-0C)
(ix) Calculate the shell side or heating medium side heat transfer coefficient. If
shell side heating medium is saturated steam then take
h'0 = 6000 W/(m2 ■ 0C)
This figure also includes fouling resistance. If hot oil is used as heating
Process Engineering Channel

medium, then use the Eq. (6.35) or Eq. (6.36) for the calculation of h0.
(x) Determine the overall heat transfer coefficient by Eq. (6.42).
(xi) Calculate the required heat transfer area.

<Ph
A
req = (6.43)
U„AT„.
@ProcessEng

Heat transfer area provided A(jpro = N, 7t d0 L

Find the % Excess heat transfer area.

A opro.
Excess heat trasfer area = -1 x 100
4eq
 Introduction to Process Engineering and Design

It should be in between 10 to 20%. If it is not, then change the value of

A0pro., either by increasing the tube length or by increasing number of tubes.
An increase in tube length will keep the tube side heat transfer coefficient
unchanged but it will increase the value of Apt. Increase in number of tubes
will decrease the value of /z, and also of h0, if hot oil is used as heating
medium but it will decrease the value of Apr In any case, both pressure
balance calculations and heat transfer coefficient calculations must be re-
peated.
(xii) Find the shell side pressure drop Aps. It should be less than the maximum
allowable value.

Example 6.6
Design a vertical thermosyphon reboiler which must provide 10 000 kg/h of zr-pentane
vapour to a distillation tower at 10 bar a pressure.
Solution:
Determination of boiling point of pentane:
Antoine equation4 for n-pentane

In p..=A , where, p.. in torr, 7 in K

(7 + C)

iIn p = 15.8333
i< - 2477.07
v
T - 39.94

pv=p,= 10 bar = 7500.6 torr

T = 398.38 K= 125.40C
Heat duty, <j)= wA x 1.05 (5% heat loss)
where, A = Latent heat of vaporization at the boiling point
Latent heat of vaporization of pentane at 125.40C:
At 250C, A,, = 366.512 kJ/kg
Critical temperature of pentane, tc = 1970C, (Ch-3, of Ref. 2)
From Watson's equation.
_ \0.38
'2
A^ = A|
Process Engineering Channel

0.38
125.4 + 273
197 + 273
= 366.512 = 366.512x0.7167
/ x
25 + 273
197 + 273 ' /
@ProcessEng

= 262.68 kJ/kg
Heat duty, 0 = 1.05 x 10 000 x 262.68
(p = 2758 140 kJ/h = 766.15 kW
0
Let = 39.6 C. Assume that this value of A^ is less than and close to the critical
temperature drop.
 Process Design of Heat Exchangers 241

Average temperature of heating medium

% = % + Ar= 125.4 + 39.6 = 1650C
From Steam Tables, for the steam temperature ts = 1650C, sturation steam pressure =
700 kPa and latent heat of condensation of steam
4 = 2064.9 kJ/kg

(p, = ms \

. = 766.15 _ 0 371 kg/s= 1335.6 kg/h

2064.9
For the first trial calculations, assuming overall heat transfer coefficient U0 = 1000
W/(m2 ■ 0C)

ip, 766.15 xlO3

=
pro
U0ATm 1000x39.6
Apro = 19.3472 nr = Nlnd0L
Let length of tube L = 6 ft = 1.8288 m
d0 = 25.4 mm
19.3472 =Ntx kx (0.0254) x 1.8288
Nt= 132.57 = 133 tubes
For 25.4 mm OD tube, 31.75 mm tube pitch (P/d,, = 1.25) triangular pitch arrangement
and 1-1 shell and tube heat exchanger,
Shell ID, Di = 438 mm (From Table 6.1 (f))
Assume recirculation ratio = 4
Available differential head
AP.dv=L(pL-PJg (6.66)
0 3
Pi = Density of liquid pentane at 125.4 C = 626 kg/m
Density of pentane vapour at 10 bar a pressure and at 125.40C

pM 10x72 273
Pv
~ ~RT~ (273 + 125.4) 1.013 25x22.414

pv = 21.724 kg/m3
Average density of liquid-vapour mixture

HVo'Vi)
(6 67)
p™ = rO -
Process Engineering Channel

*I
Vj = Specific volume of liquid at inlet

V) = — = 1.597 44 x KT3 m3/kg

Pl
For a recirculation ratio = 4
Flow rate of liquid at the outlet of reboiler
@ProcessEng

=4x 10 000 kg/h = 40 000 kg/h

Flow rate of vapour at the outlet of reboiler mv0 = 10 000 kg/h

Specific volume of vapour at outlet
 Introduction to Process Engineering and Design

10 000 40 000
+
'Ko'PV+WLO'PL 21.724 626
K,=
m
vo + mLo 50000

V; = 0.010 4843 m3/kg

0.010 4843
In
1.597 44x10 -3
= 211.715 kg/m3
Pav -3
0.010 4843-1.597 44 xio

APav = 1.8288 x (626 - 211.715) x 9.81 = 7432.5 Pa

Assume that higher sizes of the piping will be used in between base of distillation column
and thermosyphon reboiler.
Pressure loss in the system s Tube side pressure drop, Ap,.
Tube side pressure drop,

\- m
L\ P Pav ul
= Np 87, + 2.5 (6.27)
dj )[pw

Np = l, - sl,pav = 211.715 kg/m3

P
Tube inside diameter
7,- = 22.098 mm (16 BWG tube)
Tube inside flow area

6,,= —x ~df = —x-( 0.022 098 )2 = 0.051 m2

' Np 4 ' 14

Tube side mass velocity

m
■ ^ • 50000x—1—
m vo + mLo 3600
a. 0.051
= 272.33 kg/(m • s)
G
' 272.33
Process Engineering Channel

Tube side velocity, u, = —— =

pav 211.715
= 1.2863 m/s

(1:0, 0.022 098x272.33

Re = = 7 = 50 149.6
Pl 0.12 xlO-3

(Kern suggests to use liquid viscosity, instead of viscosity of liquid-vapour mixture)

@ProcessEng

Jf = 3.2 x 10~3 (From Fig. 6.13)

1.8288 2Il.715xl.28632
A/?, = 8 x 3.2 x 10-3 x + 2.5 x
0.022 098

l±p, = 808.94 Pa
/S.pcl > Ap,
 Process Design of Heat Exchangers

Assume the higher value of recirculation ratio (greater than 4) and by trial and
calculations find the value of recirculation ratio for which Apav = Apr
Trial I: Assume circulation ratio = 15.5

= 15.5 x 10 000 = 155 000 kg/h, mvo = 10 000 kg/h

10 000 155 000

21.724 y 626
V = = 4.2904 x 10-3 m3/kg
165 000
™3//kg
v-3 m
v;- = 1.597 44 x 10^

ln(( 4.2904 x 10"3)/(1.597 44 x 10"3))

Pav — = 366.874 kg/m3
3 3
(4.2904 x ] 0" - 1.597 44 x 10~ )

Apav = 1.8288 x (626 - 366.874) x 9.81 = 4648.9 Pa

65 000)
3600
Tube side mass velocity, G, = - = 898.693 kg/(m2 • s)
0.051
Tube side Reynolds number

d.G. 0.022 098x898.693

Re= = = 165 494
Pz. 0.12 x 10
Tube side fraction factor, Jf= 2.64 x 10"3 (From Fig. 6.13)

„ , ., . . G, 898.693 o /
Tube side velocity u, = =— = 2.45 m/s
366.874
Tube side pressure drop
y
\/ \— m
. . f r. P Pav Ut
oc

/±Pt = Np + 2.5 (6.27)

/ , Pw y /

366.874 x 2.452
3 8288
= 1 8 x 2.64 x 1Q~ x ( '• xl + 2.5 x
0.022 098
Process Engineering Channel

= 4677.2 Pa
A
PavSAp,
Hence recirculation ratio of 15.5 is acceptable.
Heat transfer coefficients:
(a) Tube side heat transfer coefficient
Re = 165 494
@ProcessEng

CL PL
Pr = (Kern suggests to use liquid properties)

Properties of liquid pentane at 125.40C:

Specific heat CL = 2.2483 kJ/(kg ■ 0C)
Viscosity pL=0A2cP
 Introduction to Process Engineering and Design

Thermal conductivity, kL = 0.124 56 W/(m ■ 0C)

ClHl 2.2483 x 0.12 x 10"3 xlO3

Pr =
L 0.124 56
= 2.166

/ \0.I4
0 0 33
= 0.023 Re * Pr (6.19)
nw

0.124 56
h, = 0.023 x x (165 494)0-8 x (2.166)0-33 x 1
0.022 098

^ = 2503.5 W/(m2 • 0C) > 1702.6 W/(m2 ■ 0C) Take h, = 1702.6 W/(m2 • 0C)
Shell side heat transfer coefficient /?„' = 6000 W/(m2 • 0C)
(This value includes fouling resistance)

d0 In
ydi d O . I . do . . I
+ + x + x (6 42
h' 0/
2kw i~
d, "r
hi ^~
d, 7r
hul - )
Un -o

Thermal conductivity of tube maerial kw = 45 W/(m ■ K) (mild steel tubes).

Tube side fouling coefficient /t/(/ = 5000 W/(m2 ■ 0C)

25.4
0.0254 In
22.098 25.4 1 25.4 1
U0 6000 2 x 45 22.098 1702.6 22.098 5000

U0 = 900.13 W/(m2 • 0C)

Heat transfer area required

766.15x1000
= 21.494 m2
Arcq
U
^ o ATm 900.13x39.6

Pro _ 19.3472
= 0.9 < 1.1
A.eq " 21.494
Process Engineering Channel

Assume new ratio of 1.2.

1 2
Revising tube length Lrev = 6 x = 8 ft

= 8 ft = 2.4384 m
Apro =NI Kd0L = 133 x ^-x 0.0254 x 2.4384 = 25.8786 m2
For the new tube length and with recirculation ratio = 15.5
@ProcessEng

7 4784
An = 4648.9 x £^£21 = 6198.53 Pa
ax
1.8288
Tube side pressure drop,
Ap, = 5182.63 Pa
Apav > Ap,, hence assume the higher value of recirculation ratio.
 Process Design of Heat Exchangers 245

Trial: For the recirculation ratio = 17

mUl = 17x 10 000 = 170 000 kg/h, mv0 = 10 000 kg/h

Specific volume of liquid-vapour mixture at the outlet of reboiler

170000 10000
+
626 21.724
v; = = 4.066 x H)"3 m3 kg
180000

' 4.066 x 10"3

In
1.597 44x10 -3
Average density, pav =
av
(4.066 x 10"3 -1.597 44 xlO-3)
= 378.46 kg/m3
Apav = 2.4384 x (626 - 378.46) x 9.81
= 5921.33 Pa
Tube side pressure drop:
Tube side mass velocity

180 000/3600
G, = = 980.392 kg/(m ■ s)
' 0.051

djG, 0.022 098x980.392

Re =
R 0.12x10 -3

= 180 539.2
y/ = 2.4x lO"3
G,
u, = = 2.59 m/s
Pav

3 2.4384 ^ 378.46 x 2.592

Ap, = 1 x ^8x2.4x10 x + 2.5 x
0.022 098 I

= 5862.75 Pa
Apav = Ap,
For the recirculation ratio = 17
Process Engineering Channel

Re,- = 180 539.2

\0.8
180539.2
h: = 2503.5 x = 2684 W/(m2 ■ 0C) > 1702.6 W/(m-2 ■ o/
0
C)
, 165 494 .

Take /?, = 1702.6 W/(m2 • 0C)

Heat transfer area required Ared = 21.494 m2
@ProcessEng

v l
Excess heat transfer area = x 100
A-eq

25.8786
-1 x 100
21.494
= 20.4%
 Introduction to Process Engineering and Design

Shell side pressure drop Aps:

For the condensation of saturated steam, shell side pressure drop is calculated by equa-
tion

APS = 0.5 x 8 x 7/1 t l] (6.41)

UJ
Shell side Friction Factor,^:
To find this factor, first shell side flow area must be determined.

(P, - d0 )DSB,
As = — — (6.29)
'i
Let Bs = Baffle spacing = = Shell inside diameter
Bs = Ds = 0.438 m, d0 = 25.4 mm, Pt = 31.75 mm

31.75-25.4
Ak = x 0.438 = 0.038 37 in2
31.75

Shell side mass velocity G, = = 9.67 kg/(m2 • s)

5
As 0.038 37

Density of steam pv = ^
Specific volume
From Steam Tables specific volume of saturated steam at 700 kPa pressure, vs
= 0.272 68 m3/kg
pv = 3.6673 kg/m3
Gs 9.67 .
li. = — = = 2.64 m/s
pv 3.6673

Equivalent diameter, dl, = —P,2 - 0.907 d2) (6.29)

d
o

1 1
dp = (0.031752 - 0.907(0.0254)2)
c
0.0254
de = 0.0183 m
Shell side Reynolds number;
Process Engineering Channel

deGs
Re =
p
0
Viscosity of steam at I 65 C and at 700 kPa pressure = 14.5 x 10"6 (N • s)/m2
(Table 3.302, ofRef. 2)

0.0183x9.67
Re..9 = — = 12 204.2
14.5 x 10
@ProcessEng

Jf = 4.78 x 10_2 (For 25% baffle cut) (Ref. Fig. 6.15)

->( 0 438 ^^2 4384^ 3.6673 x2.642

Ap = 0.5 x 8 x 4.78 x lO"2 x
V 0.0183 A 0.438 ) 2
Aps = 325.6 Pa = 0.326 kPa < < 13.8 kPa
It is well within permisible limit.
 Process Design of Heat Exchangers

6.7.3 Criteria of Selection between Kettle Type Reboiler

and Thermosyphon Reboiler

(i) Boiling fluid side (process fluid side) pressure drop in kettle type reboiler
is negligible. While the same is high and significant in thermosyphon
reboiler. Hence with vacuum distillation, kettle type reboiler is preferred.
Thermosyphon reboiler is not preferred for use with absolute pressure be-
low 0.3 bar. For example, in separation of the mixture of monochloroacetic
acid and acetic acid by distillation, kettle type reboiler is the only choice.
Cracking temperature of monochloroacetic acid is 120oC and is obtained
as the bottom product. Vapour pressure of monochloroacetic acid at 1180C
is 60 torr. Hence, to restrict the boiling point of monochloroacetic acid
below 120oC, pressure drop in distillation column plus pressure drop in
over head condenser plus pressure drop in reboiler plus pressure drop in
associated piping must be less than 60 torr (0.08 bar). So, kettle type reboiler
is the only choice.
(ii) If the viscosity of bottom product of distillation column is very high, then
thermosyphon reboiler cannot be used. In such a case forced circulation
reboiler is preferred.
In fatty acid separation in a distillation tower under vacuum, forced circula-
tion reboiler is used due to viscous nature of fatty acids. However, for the
vacuum and corrosive system with highly viscous bottom product kettle
type reboiler is used. For example: separation of pure POCI3 (phosphorous
oxitrichloride) from treated crude POCI3, residue or bottom product of dis-
tillation is highly viscous. Thermosyphon reboiler cannot be used for this
application.
(iii) With atmospheric and high pressure distillation column thermosyphon
reboilers are preferred as size and fixed cost of thermosyphon reboiler is
less than the same of kettle type reboiler. Because of the fluid circulation,
thermosyphon reboiler provides higher heat transfer coefficient than kettle
type reboiler. Even for the same value of heat transfer area, fixed cost of
kettle type reboiler is higher than the same of thermosyphon reboiler.
(iv) If the ratio of vaporization rate required to mass flow rate of residue (bot-
tom product of distillation column) is 0.8 or above, kettle type reboiler is
Process Engineering Channel

prefered. Kettle type reboilers are also use as "Vaporizers" in industry.

Thermosyphon reboiler cannot be used as vaporizer. Separation taking place
in kettle type reboiler can be considered as equivalent to one theoretical
stage. If Murphree efficiency of the column is 50% (approx.), it can result
in reduction of two trays.
@ProcessEng

6.8 TINKER'S FLOW MODEL

All the latest methods (Ex. Bell's method), for the process design of without
phase change heat exchangers are based on Tinker's flow model. If there is no
phase change in shell side fluid then shell side heat transfer coefficient and shell
side pressure drop in all recent methods are calculated based on this model. In
 Introduction to Process Engineering and Design

F. -

0 0 \
fh
□ (h 0

0/
Q il
\v
□ \\^ O O JJ
o
c
^\\\\\\\\\\\\\\\\\\\\\'^
Fig. 6.27 Tinker's Flow Model413

old methods like Kern's method it is assumed that entire shell side fluid is flow-
ing across the tube bundle and between the baffles. But actually shell side fluid is
flowing in various ways. In Tinker's flow model shell side flow is divided in five
different steams.
1. Stream A
Stream A is the tube-to-baffle leakage stream or it is the fraction of shell side
fluid flowing through the clearance between lube hole in baffle and tube outside
diameter. This stream does not bypass the heat transfer area (outside area of tubes)
and hence it does not create any adverse effect on the value of heat transfer coef-
ficient. However, it makes the significant difference in pressure drop (loss). When
stream A leaves this clearance it forms free flowing jet. Hence, boundary layer
separation occurs and considerable friction loss or pressure drop takes place.
Effect of stream A must be considered in the calculation of pressure drop.
2. Stream B
Stream B is the actual cross flow stream or it is the fraction of shell side fluid
which is flowing across the tube bundle and between the baffles. In Kern's method
and other old methods it is assumed that entire shell side fluid is flowing like
stream B.
3. Stream C
Stream C is bundle to shell bypass stream or it is the fraction of shell side fluid
flowing through the clearance area between shell inside diameter and tube bun-
Process Engineering Channel

dle. Stream C is the main bypass stream, (bypassing the heat transfer area). This
clearance area provides low pressure drop path for the shell side fluid. Hence, %
of shell side fluid bypassed through this clearance area is quite significant. It is
maximum with pull through floating head heat exchanger and minimum with
fixed tube sheet heat exchanger. Amount of stream C can be reduced consider-
ably by using sealing strips which are attached on inside surface of shell. They
provide the partial blockage or the additional resistance in the path of stream C.
@ProcessEng

There is no stream designated as stream "D".

4. Stream E
Stream E is the baffle to shell leakage stream. It is a part of shell side fluid flow-
ing through the clearance between the edge of baffle and shell wall. Like stream
C, this stream is also bypassing the heal transfer area and hence reduces shell
 Process Design of Heat Exchangers

side heat transfer coefficient. But amount of stream E is lesser than amount of
stream C. Normally the clearance between baffle outside diameter and shell in-
side diameter is in the range of 1.6 to 4.8 mm while clearance between tube
bundle and shell inside diameter is in the range of 10 to 100 mm.
5. Stream F
Stream F is the pass-partition bypass stream. In tube sheets where pass partition
plates are attached, in that portion tubes can not be provided. In multipass heat
exchangers one can find more number of gaps in tube bundle. Stream F is the
fraction of shell side fluid flowing through these gaps. If the gap is vertical it
provides low pressure drop path for fluid flow. Just like stream C and stream E,
this stream is also bypassing the heat transfer area and reduces shell side heat
transfer coefficient. Amount of stream F and its adverse effects are significant in
multipass heat exchanger. To reduce the amount of this stream sometimes dummy
tubes are used.

6.9 AIR COOLED HEAT EXCHANGERS AND

AIR HEATERS

6.9.1 Introduction

Atmospheric air (having temperature varying from 20 to 450C, depending on

season) can be used as cooling medium if the process fluid is to be cooled up to
60oC. If it is to be cooled below 60oC, then atmospheric air cannot be used as
cooling medium, as minimum driving force required for heat transfer in air-cooled
heat exchanger is 10oC.
Advantages and disadvantages of air as a cooling medium over water as a
cooling medium are given in previous section. (Sec. 6.3.2.3)
As shown in Fig. 6.28, air cooled heat exchanger consists of banks of finned
tubes over which air is blown by forced draft fan or drawn by an induced draft
fan. Forced draft fan is mounted below and induced draft fan is mounted above
the lube bundle. Tube bundle consists of tubes with spiral wound transverse fins
in the majority of applications. Forced draft unit consumes less power. Induced
draft provides comparatively even distribution of air across the bundle since the
Process Engineering Channel

Hot-fluid ^ High-fin
^Inlet nozzle Air tubes
Stationary Floating
header -*kieader

Hot-fluid Fan Fan Supporting

outlet nozzle
Column
@ProcessEng

^-Plenum -Fan ring

<—Air
s
Right-Angle Right-Angle
Gear Drive HM Motor Gear Drive 4k Motor

Fig. 6.28 Forced Draft Air Cooled Heat Exchanger

 | 250 Introduction to Process Engineering and Design

air velocity approaching the bundle is relatively low. Percentage recirculation of

hot exhaust air is less in induced draft unit compared to the forced draft unit since
the exist air velocity is several times that of forced draft unit. Induced draft ar-
rangement gives more protection to heat transfer surface against rain fall, snow
fall, sleet, etc.
If the difference between process fluid outlet temperature (required) and am-
bient-air temperature is less than 30oC, induced draft unit is preferred because of
the less % recirculation of hot exhaust air. But if the same is more than 30oC,
Forced draft unit is preferred as it consumes less power. 3/4 in (19.05 mm OD)
and 1 in (25.4 mm OD) tubes are more commonly used. Fin spacing from 3.6 to
2.3 mm (7 to 11 per linear inch) and triangular pilch from 43 to 63.5 mm are
common. Tube ends are left bare to permit the attachment or insertions of tubes
into appropriate holes of box type headers. Fin material can be aluminium, cop-
per, mildsteel, stainless steel, etc.
The same heat exchanger is also used for heating the air by saturated steam or
cooling of the atmospheric air by chilled water. Hot air is used as drying medium
in the dryers while chilled air is used for air conditioning.
For all above mentioned applications of the air heat exchangers, worst condi-
tion or design condition is different.
(a) If atmospheric air is used as cooling medium then for the design calculation
the maximum possible temperature of ambient air in the entire year must be
considered.
(b) If air is heated by saturated steam to get the hot air for dryer, then for the
design calculations minimum possible temperature of ambient air in the
entire year must be considered.
(c) When atmospheric air is cooled to lower temperature (say to 140C) by chilled
water, then sizeable percentage of heat duty is utilized in the condensation
of water vapour which is always present in atmospheric air. Hence for this
case, for the design calculations atmospheric air with the maximum possi-
ble absolute humidity (and with corresponding temperature) must be con-
sidered.
Fins are used to increase the heat transfer area and thereby to decrease the size
of heat exchanger required. For the heat transfer, fin area is not as effective as
bare tube area. Hence, in design calculations to consider the effectiveness of fin
Process Engineering Channel

area, fin efficiency is determined.

Design method for air side or finside is completely different from the same
used for shell and tube heat exchanger, but for finding tube side heat transfer
coefficient and tube side pressure drop same correlations are applicable that are
used for a shell and tube heat exchanger.

6.9.2 Method for Finding Air Side or Fin Side Heat

@ProcessEng

Transfer Coefficient and Pressure Drop

(a) Air or finside heat transfer coefficient:

Find the equivalent diameter by using following equation

2(fin area + bare lube area)

(6.69)
n (projected perimeter)
 Process Design of Heat Exchangers 251

For example:
Tube OD ~ 19.05 mm. Fin OD = 38 mm
Tube pitch = 43 mm, Fin height = 9.475 mm
Number of fins per liner inch = 8
Fin thickness = 0.889 mm
Type of fin = Spiral wound transverse fin
Fin area per unit length of tube

= ^ (Fin OD2 - Tube OD2) x 2 x No. of fins per one metre of

tube length (6.70)

- (0.0382 - 0.019 052) x 2 x x 1000

4 25.4

m
= 0.534 86
m of lube length

Bare tube area/m of one tube = k d0x 1 - Jidjj-x no- (6.71)

where, d0 = OD of bare tube, m
tf = thickness of fin, m

1000
tif = number of fins per 1 m of tube length = 8 x
25.4
Bare tube area

0 889
= ^x 0.019 05 x 1 -^x 0.019 05 x - xllx8x1000
1000 25.4
= 0.043 09 nr/m of one tube
25.4 mm
(b) Projected Perimeter:
Projected perimeter
= 2(Fin OD - tube OD) xnf-lx{\ - tf-nf) (6.72)
= 2(0.038-0.01905) x 8

1000 3 1000
X -2 1 -0.889 xl(r x8x
25.4 25.4
Process Engineering Channel

= 10.497 m/m of one tube

2 x (0.53486+ 0.043 09)

d„ = = 0.035 05 m 2.286 mm
ttx 10.497
Fig. 6.29 Projection of
Shell side or air side flow area:
Finned Tube
as = Air facing area - Area occupied
@ProcessEng

by finned lubes
Air facing area = Length of area x width of area
= Tube length x width of area
In majority of applications width of air facing area is kept equal to tube
length.
 Introduction to Process Engineering and Design

For example let tube length L = 1500 mm

Air
(in the previous example) and W = L =
1500 mm
as = WL - np x d0x L- np
(fin OD - lube OD) tj- ■ iij L
' (6.73)
where, ^ = Number of tubes in bank ir
perpendicular to the direc-
tion of flow of air Air
rir— Number of fins per 1 m of
Fig. 6.30 Airfacing Area
tube length

^ =3488 =35
Let W = 1510 mm (revised) for np = 35 tubes in one bank
W = {np - I) x /?, + Fin OD + x
W = (35 - 1) x 43 + 38 + jc or x = 10 mm
Hence there will be 5 mm clearance on either side.
as = 1.51 x 1.5 - 35 x 0.019 05 x 1.5 - 35 x (0.038 - 0.019 05)

1500
x (0.889 x 10"3) x 8 x
25.4
2
a, = 0.986 31 m
(c) After calculating de and as, calculate the air side mass velocity

IK.
(6.74)
Ch

where, ma = Mass flow rate of air, kg/s

as = Air side or shell side flow area, m"
(d) Calculate shell side or air side Reynolds number

deGs
Re = (6.75)
Process Engineering Channel

where, de = Equivalent diameter, m

Gs = Mass velocity of air, kg/(m2 • s)
ju = Viscosity of air at average temperature, kg/(m • s)
(e) Calculate air side Prandtl number

CPp
Prandtl number for air, Pr = (6.76)
@ProcessEng

where, Cp = Specific heat of air, J/(kg • 0C)

[1 = Viscosity of air, kg / (m • s)
k = Thermal conductivity of air, W/ (m • 0C)
(f) All properties must be determined at average temperature on shell side.
Calculate fin side or air side heat transfer coefficient (clean and for 100%
fin efficiency)
 Process Design of Heat Exchangers

h^j, — --l/3
kpr"' (6.77)
lJ-Jf d
e
,2 o.
where, hf = Heat transfer coefficient, W7 (m" • 0C) (clean)
Jf = Factor for heat transfer coefficient
k = Thermal conductivity of air, W/(m • 0C)
de = Equivalent diameter, m
Pr = Prandtl number of air
Jf, factor of heat transfer coefficient can be claculated by following equa-
tion.
a7324
Jf = 0.085 2072 Re (6.78)
(g) Calculate dirty fin side heat transfer coefficient, fy (for 100% fin efficiency)

yr =i- + T~ (6-79l
hf hf hdo

where, hdo = Shell side fouling coefficient, W/(m • 0C)

hf = Dirty fin side heat transfer coefficient, W/(m2 • 0C)
(h) Calculate dirty fin side heat transfer coefficient based on inside heat trans-
fer area and considering fin efficiency

h
f
hf = (Q x Af+ A'0) — (6.80)
A
where, h'f = Dirty fin side or Air side heat transfer coefficient based on
inside heat transfer area, W/(m " 0C)
Q. = Fin efficiency
'y
Af = Total fin area, m"
hf = Total bare tube area, m2
'y
A/ = Inside heat transfer area, m"
(i) Fin efficiency Q can be determined from Fig. 6.31 in which graph is drawn

h
, f re
for (re - rb) vs Q for the different values of —
r
h/n}'/, h
Process Engineering Channel

Fin OD Tube OD
where, re = , m, rb = , m

Fin thickness
yb= ^ .m

km = Thermal conductivity of fin material, W/(m * 0C)

@ProcessEng

hf = Dirty fin side heat transfer coefficient determined by Eq.

(6.79), W/(m2 • 0C)
In{u) = Modified Bessel function of the first kind and order n,
dimensionless
 Introduction to Process Engineering and Design

Q= A ("h)-PiK\ ("/,)
ln("h) + PiKu(ub)
0.9
P~~ /2/3("e,//2/3,"c''
-n
0.8 ('i
n =
0.7 -i

= uh(r,Jrh)
0.6

G 0.5

0.4

0.3
.6
1.8 2.1
0.2

0.1

1.0 2.0 3.0 4.0

(re-rb)^lhflkmyh
(a) Efficiency of Annular Fins of Constant Thickness

'2/3 (Uh ) - ^'2/3 ("/) )

a=
3 «,, [ 1 - (u, lu. 3)] A/3 + 1/3

0.8 2('-e -rb)^hl tkyb

0.7 -

«e=Wi)3'2
0.6

0.5 r n r t 1 I T
Process Engineering Channel

0.4
1

0.3 <0

0.2
4.0
@ProcessEng

0.1

1.0 2.0 3.0 4.0

(C-rh ^h,f/km 37,

fbj Efficiency of Annular Fins with Metal Area for Constant Heat Flux
 Process Design of Heat Exchangers

-r n = \l2-,y = yh ;«h =(<;, • )y]l</"Vh

IA) = (tan/i)/«,,
n = l/3;y = ybylr/re -
4 '2/3 '"a )
B) <uh =4/3(rf -rh)^hj'lky
3
II.N "A A/3("A)
n = 0'y = y (r/r. -r)
(C) 2/1 ("/.)
^= ;== 22(»V
(c -r^Jh/Zky^
0.7

117,

0.5 1 1__L 1 L
4. — 1-
11.4

0.3

n = -\;y = yb (r/r. - r. ) (D)

12 4 '2 iuh)
^= ;«/, = 4 ( r - r,,)
'1 ("a)
0.
n = ±°°;y = yt (r/re -rb) (E)
2 {re-rb)
n= '•"h = (>a - rh ) J h f I tyh
' = J'+4"i
.0 2.11 3.0 4,(1

(re-rb)ylh}/kmyb
(c) Fin Efficiency of Several Types of Straight Fin

Kn(u) = Modified Bessel function of the second kind and order n,

dimensionless
u = A function
(5 = Constant
(j) Determine the tube side heat transfer coefficient /?,. For this determination,
Process Engineering Channel

the same correlations are applicable which are used for shell and tube heat
exchangers. Decide the tube side fouling coefficient hj.
Find the overall heat transfer coefficient based on inside heat transfer area,
U,

1
U; = (6.81)
@ProcessEng

1
' +J-+
hp hi hid

(k) Then calculate the inside heat transfer area required

fa
A; = (6.82)
UiAXn
 Introduction to Process Engineering and Design

u iu,, =V2(i;-r^Jhf/ky
+ , +4/3n
n = -l-,y=yt{r/rl, -rh)
(U) „ =———s
u
4 \ b' % = 2J2 2y 1 . j ,,,,
• <; - 'i 1V%
"t 'l<"6) 3

,1 = 0:.i> = yk \{r/i^r~)
|C> £2„ = 2 '1 («/.)

"6 -'i) Jhf 'ky

1,"

rN

1.4

i = i/2;y = y/.; m
12 = (Ian ft «6 )/ub ; llt = -fi ( r, - r,,) JUJTicy rA

4.0

ire-rb)ylh'flkmyb
(d) Efficiency Curves for Four Types of Spine

Fig. 6.31 Fin Efficiencies for Various Types of Fins5

where, (j), = Total heat duty, W

ACT = Mean temperature difference, 0C
A^n = F, A^n
where, F, = LMTD correction factor for cross flow can be determined,
Process Engineering Channel

from the Fig. (6.32)

(1) Heat transfer area provided (inside)
A i = N, TrdjL
Provided area should be greater than required area. Ideally provided area
should be greater by 10 to 20% than the required area.
(m) Calculate, the tube side pressure drop by using the same correlation that is
used for shell and tube heat exchanger. It should be less than maximum
@ProcessEng

allowable pressure drop.

(n) Calculate the volumetric equivalent diameter by following equation.

4 x net free volume

D
ev - / \ (6.83 a)
np
(Af + A0)
\nt /
 Process Design of Heat Exchangers

Case A
0.9 %

^ 0.8 r. -T-
R= =4 1.5 l.ll 11.8 0.6 0.4 0.2
fv-f
0.7

0.6 *2
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
S=(i2- ^/(r, - 0) 'a) Both Fluicls Unmixed

Case B
0.9
%
J I k
^ 0.8 r. —t
R= =4 1.5 1.0 0.6 0,4 0.2
r,2 -i
i'
0,7
1 I F
0.6
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 *2
s=(i2-ily(Ti-il) (b) One Fluid Mixed,
Other Fluid Unmixed.

Case C
0.9 71
0.8 r. -r.
R= =4 0.6 0.4 0.2
(,-I h-
0.7

0.6 72
0 0,1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
(c) Both Fluid Mixed.
5=((2-'I)/(71-'I)
1.0
Case D %
0.9

0.8 M i \ \i
7,-72 Tn hi
R=- -=4 31 21 l.s) l.o\ oAo.6\oAo.2i
0.7 h-'l <
Process Engineering Channel

0.6 111 Ml 1 n M \m
Ti
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 (c) Two-pass Counter flow,
S=('2-'.)/(7i-'i) Shell Fluid Mixed,
Tube Fluid Unmixed.
Fig. 6.32 Cross F/ow Temperature Difference Correction Factors5

Net free volume

@ProcessEng

= W x L x x' - rip x ^dl L - np x ^ (Fin OD2 - dj) x tfnfL (6.83 b)

where, W = Width of Air facing area, m

L = Length of tube, m
x' = Horizontal distance between two vertical bank (see
Fig. 6.33)
 Introduction to Process Engineering and Design

-Vi

.Sr < x
Fin OD = 38 mm

5/. = 57- = 43 mm

Fig. 6.33 Finned Tube Arrangement

For equilateral triangular pitch arrangement

x' = P, sin 60
ti, = Total number of tubes
np = Number of tubes in one bank, perpendicular to the direc-
tion of the flow of air
d0 = Outside diameter of (bare) tube, m
tf = Thickness of fin, m
rif = Number of fins per I m of tube length
Ai- = Total fin area, m2
= Total bare tube area, m2
For the previous example:
K
Net free volume = 1.51 x 1.5 x 0.037 24 - 35 x — (0.019 05)2 x 1.5
4

- 35 x (0.0382 - 0.019 052) x (0.889 x K)"3)

x 8x1Mx1.5 = 0.0569 m3
I 25.4
Process Engineering Channel

Ai- = (0.534 86 m_/l m of one tube) x L x n,

= 0.534 86 x 1.5 x n, = 0.802 29 x n, m2
Ay = (0.043 09 m2/m of one tube) x L x «, = 0.064 635 n, m'

(Af + Ay )— = (0.802 29 + 0.064 635) x 35 = 30.3424 m2

n,
@ProcessEng

4 x 0.0569
D„..
ev = = 0.0075 m
30.3424
Reynolds number for the calculation of pressure drop

D
ev Gs
Pes = (6.84)
P
 Process Design of Heat Exchangers

where, Gs = Mass velocity of air based on flow area as, kg/Cm" • s)

/A = Viscosity of air at average temperature, kg/(m • s)
Calculate the air side or shell side pressure drop

fG;Lr / \0.4 / 0 \ 0.6

s,
&Ps = (6.85)
Dev x p >7- y

Aps = Pressure drop, N/m2

/= Air side friction factor can be calculated by following
equation.
/= 1.085 58 x /fcr0128025 (6.86)
SL = Center to center distance to the nearest tube in the next
bank, m (as shown in Fig. 6.33)
ST = Pitch in transverse beak, m (as shown in Fig. 6.33)
Lp = Effective path length of pressure drop, m
Lp can be determined by following equation
n
/ i
L = x x— (6.87)
' 17
Hp
Calculated pressure drop should be less than maximum allowable pressure
drop.

Example 6.7
Mobil therm oil is used as heating medium in chemical industry. Its operating range is
from-1.10C to 3160C.
It is required to cool 9000 kg/h of mobil therm oil from 260oC to 200oC by using
atmospheric air as a cooling medium in air cooler. Design the suitable air-cooler.
Properties of Mobil therm oil at 230oC temperature
Density, p = 850 kg/m3
Specific heat, CL = 2.5 kJ/(kg • 0C)
Viscosity, p = 0.595 cP or mPa • s
Thermal conductivity, A; = 0.1159 W/(m • 0C)
Solution:
Heat duty required
Process Engineering Channel

0, = m CL At = 9000 x 2.5 x (260 - 200)

= 1350 000 kJ/h
= 375 kW
Assume maximum possible temperature of atmospheric air in the area as 480C.
Let outlet temperature of air = 750C
Mass flow rate of Air required
@ProcessEng

. = ^ ^ 375
" CpaAt Cpa (75-48)
Specific heat of air at 61.50C
Cpa = 0.25 kcal/(kg ■ 0C) = 1.0467 kJ/(kg ■ 0C) (Ref. 9)

ma = 13.2692 kg/s = 47 769 kg/h

 Introduction to Process Engineering and Design

A'4 Mean temperature difference

A'4 = A4 ' F,
Oil temperatures are very much greater than air temperatures hence forced draft fan can
be selected to reduce the power consumption. Atmospheric air will enter from the bot-
tom of tube bundle. Hot oil is also introduced from the bottom of the header. Hence,
overall there is a cocurrent contacts. But, actually there is cross flow contact with multipass
flow of oil.

(260 - 48) - (200 - 75) 212-125

A'4 = : : = : = 164.69 0C
n
'260-48 212 \
In In
200 - 75 125 j

Ti -% 260-200
R = — -= =2.222
h ~t\ 25 - 48

?2 -t\ 75 - 48
S= -= =0.12736
T, 260-48

F, = 0.98 (From Fig. 6.32 a)

A^ = 161.396 0C
Evaluation of h0:

2 (fin area + bare tube area)

Equivalent diameter de = ; ; (6.69)
tt (projected perimeter)
Let tube OD = 19.05 mm.
Type of fin = Spiral wound transverse fin
Fin OD = 38 mm. Tube pitch = 43 mm (Equilateral triangular )
Number of fins per linear inch = 8
Fin thickness = 0.889 mm
Fin and tube material = mild steel

Fin area/1 m of one tube = 2 x (fin OD2 - r/2)x No. of fins per 1 m length (6.70)

Af = 2 x - (0.0382 - 0.019 052) x 8 x

^ 4 25.4
Process Engineering Channel

Au =0.534 86 m2

Bare tube area/1 m of one tube = An{ = nd0 x 1 - 7id0tfnf (6.71)

(where itj = no. of fins/1 m of one tube)

Aol = 71x0.01905 x 1 - ^x0.019()5 x(0.889x 10-3)x8x 1000

25.4
@ProcessEng

Aoi = 0.043 09 m2
Projected perimeter per 1 m of one tube
= 2 (fin OD - d0) xnf-2(l-tf nf) (6.72)

= 2(0.038-0.019 05)x 8 x - 2| 1 - 0.889 x 10"3 x 8 x-^1 = 10.497 m

25.4 V 25.4 7
 Process Design of Heat Exchangers 261

2(0.534 86 + 0.043 09)

dp = = 0.035 05 m
TTX 10.497
Flow Area:
For the first trial calculation.
Let tube length = 900 mm = L
and width of air facing area , W = 900 mm
Let np = number of tubes in one bank, perpendicular to the flow of air

_ fL 900 .,on{VI
nn = — = s 20.93
' pt 43
Let np = 21
W = (np - 1) /?, + Fin OD + x
W = 20x43 + 38 +x
x = 2 mm
Let VL = 910 mm
A" = 12 mm (Revised)
Flow area
as = WL-npxd0x L-np (fin OD - tube OD) tf nf L (6.73)
= 0.91 x 0.9-21 x 0.019 05x0.9-21(0.038-0.019 05)

x 0.889 x 10"3 x 8 x x 0.9

25.4
= 0.358 67 m2

m 47 769/3600
Mass velocity, C, = = = 36.995 kg/(m~ ■ s)
5
' ' as 0.358 67

deG,
Reynolds number. Re = — (6.75)

Viscosity of air at 6L50C

iua = 2000 x 10-7 P = 2000 x lO"8 kg/(m • s)
(Figure 3.42 of Ref. 2)

0.035 05 x 36.995
Re = = 64 834
Process Engineering Channel

2000 x 10

Factor for heat transfer coefficient

Jf = 0.085 2072 Re01224 = 0.085 2072(64 833.14f1224 (6.78)
= 284.865
Clean heat transfer coefficient, for 100% fin efficiency
@ProcessEng

hf = JfjLpr"3 (6.77)
de
Prandtl number of air at 61.50C

Cpa f+a
Pr =
K
 Introduction to Process Engineering and Design

Thermal conductivity of air at 6l.50C, k = 0.028 784 W/(m • k)

(Table 3.314, ofRef. 2)

1.0467 x 2000 xlO"8

Pr = x 103
0.028 784
= 0.7273

0.028 784
hf = 284.865 x x (0.7273)1/3
* 0.035 05
= 210.38 W/(m2- 0C)
Dirty fin side heat transfer coefficient

TV =TL + TL (6.79)
hf hf hdo

hdo = 5000 W/(m2 • 0C) (From Table 6.10)

1 1.1
hf 210.38 5000

hf = 201.885 W/(m2 • 0C)

Dirty fin side heat transfer coefficient based on inside heat transfer area and fin effi-
ciency.

h
f
hj! = (QxA/ + A;)-^- (6.80)
A-
Af = ntAf L, where, /?, = Total number of tubes
Total fin area Af = n, x 0.53486 x 0.9 = 0.481 374 n, m2
Aq = Total bare tube area
A; = nt Aol L = 0.043 09 x 0.9 x n, = 0.038 781 n,
A, = n, k dj L
Tube inside diameter, dj = 14.8336 mm (For 14 BWG tube)
A,- = ^(0.014 8336) x 0.9 x n, = 0.041 94 n, m2
Fin Efficiency (Q):
Process Engineering Channel

hf
Evaluation of: (re - rh) I —:—
K,)'/,

fin OD -is
where, r, = = — =19 mm = 0.019 m
^ 2 2

TubeOD ions
@ProcessEng

rh = = = 9.525 mm = 0.009 525 m

b
2 2
km = Thermal conductivity of fin material (mild steel)
= 45 W/(m ■ 0C)
 Process Design of Heat Exchangers

Fin thickness
yb = — (For fins of uniform thickness)

0.889 xlO"3
= 4.445 x I (F4 m

201 885
(0.019-0.009 525) - -,-4 =0.952
]/ 45x4.445x10-

r
e
= 1.994 75, Q = 0.67 (from Fig. 6.31 (a))
r
h
(0.67 x 0.481374 n, + 0.038 781«,) x (201.885)
h' =
}
0.04194 nf
= 1739.18 W/(m2- 0C)
Evaluation of
Tube side flow area, a,
Let no. of tubes per pass = np = 21

a. = 21, ^ ^ ,/22 =
x -c/, _ 21
oi ^ K v
x - x co nMs 336)2 = 3.629
(0.0148 i aoq v
x in-3
10"
' 4 ' 4
Tube side mass velocity,
,n 9000/3600
G, = — = — = 688.9 kg/(m- • s)
a, 3.629 xlO"3

G
rp . •. . .t t 688.9
Tube side velocity, u, = — =
' ' p 850
= 0.81 m/s
Tube side Reynolds number

dj G,
Re, =
Mo
0.0148 336x688.9
= 17 174.57
0.595 x lO-3
Process Engineering Channel

CLp 2.5x0.595x 10"3 x 103

Prandtl number Pr =
k 0.1159
= 12.8343
Using Dittus-Bolter equation
\0.I4
@ProcessEng

= 0.023 Re" * Pr" " " (6.

k
f V Mh. y

a1159
h: = 0.023 x x (17 174.57)()"8( 12.8343)0"33
0.014 8336
/7(. = 1019.15 W/(m2- 0C)
 Introduction to Process Engineering and Design

Ui = (6.81)

hf, /i, hid

U: = = 569.41 W/(m2 ■ 0C)

—^ + —^ + ^-
1739.18 1019.15 5000
Heat transter area (inside) required

<p, 375x1000
A rcg = —— = = 4.08 m2
cq
' Uj ATm 569.41x161.396
Let heat transfer area provided
A,.pro= 1.1 x A,.req = 4.488 55 m2
Heat transfer area per bank = npndiL = 2\ x /rx 0.014 8336 x 0.9 = 0.880 76 m2

4.48855
Number of banks required = = 5.085
0.882 76
Let number of banks = 5
% Excess heat transfer area = 9.83%
Total number finned tubes n, = 21 x 5 = 105
Total fin area Af= 105 x 0.534 86 x 0.9 = 50.544 m2
Total bare tube area A'0 = 105 x 0.043 09 x 0.9 = 4.072 m2
Total outside heat transfer area = 54.616 m2
Air side Pressure Drop:

Net free volume = W Lx - np x ^c/2 L - np x ~ (Fin OD2 - rf2) tfnfL (6.83 b)

where, x = Horizontal distance between two vertical banks, mm

/ = P, sin 60 (For equilateral triangular pitch arrangement), mm
/ = 43 mm x sin 60 = 37.239 mm

Net free volume= 0.91 x 0.9 x 0.037 239 - 21 x (0.019 05)2 x 0.9 - 21

x - (0.0382 - 0.019 052) x 0.889 x 10"3) x | 8 x ] x 0.9

Process Engineering Channel

4 I 25.4J
= 0.020 62 m3
Volumetric equivalent diameter

4 x net free volume

Dev = —^ (6.83 a)
np
(A,+4')
@ProcessEng

n,

4 x 0.020 63
= 0.007 555 m
21
(50.544 +4.072 )x
105
 Process Design of Heat Exchangers 265

Reynolds number for calculating pressure drop

0.007 555 x 36.995

Re = = 13 974.86
2000 xlO"8

/= 1.085 58 x tor0128025 (6.86)

/= 1.085 58 x (13 974.86r0-128025 = 0.3 1 9 86
,0.4 ,0.6
fG'L
s D„
An = (6.85)
D
evP \ST J \ST J
where. L = Effective path length for pressure drop, m

,n, 105
L x = 0.037 239 x = 0.1862 m
l>=
21

PM 1x29
Density of Air p = = 1.056 kg/m3
RT 0.0821X (61.5 +273)

0.4 0.6
0.319 86 x 36.9952 x 0.1862 ( 0.007 555 0.043
Aps = X
0.007 555x1.056 I 0.043 0.043
(For equilateral triangular pitch SL = ST = P,)
Aps = 5096 N/m2 = 519.6 mm WC > Apvniax = 350 mm WC
Discharge pressure of fans are generally less than 350 mm WC.
To decrease the pressure drop, flow area as must be increased
Let the revised tube length, L = 1200 mm
width of flow area (air facing area), W = 1200 m
Numbers of tube in one bank

_ LZOO = 27.9 = 28
n
p=
P, 43
Let np = 28
W = {np-\ )p, + Fin OD + x
Vk = 27 x 43 + 38 + x = 1200 => x = I mm
Let W = 1210 mm and x = 11 mm (Revised)
Process Engineering Channel

as = WL - npd0L - np (fin OD - dJtfUfL (6.73)

= 1.21 x 1.2-28 x 0.019 05 x 1.2-28(0.038-0.019 05)

1200
x 0.889 x 10~3 x 8 x
25.4
2
= 0.633 64 m

47 769/3600
@ProcessEng

Mass velocity, Gs = = 20.941 kg/(nr • s)

0.633 64

de Gs
Reynolds number. Re =
Pa
 266 Introduction to Process Engineering and Design

0.035 05 x 20.941
Re = = 36 699.1
2000 xlO"8

Factor for heat transfer coefficient

Jf = 0.085 2072 Re0 7324 = 187.77
Clean heat transfer coefficient, for 100% fin efficiency

hf = Jf—Pl'2, (6.77)
de

0.028 784
= 187.77 x x (0.7273)
0.035 05
= 138.674 W/(m2 • 0C)
Density finside coefficient

TL=TL + TL (6.79)
h h h
f f d0

1 1
+
hf 138.674 5000

h"/f= 134.932 W/(m2 • 0C)

/?; 134 1932

(r - rh), —— = (0.019 - 0.0095 25)
e
]] km yh 45 x 4.445 xlO"4

= 0.7782
rjrh = 1.994 75, £2 = 0.77 (Fig. 6.31(a))
Dirty fin side heat transfer coefficient based on inside heat transfer area and fin effi-
ciency

hf
^ = (£2x^+0-^- (6.80)
A-

134932
= (0.77 x 0.534 86 x 1.2 x n, + 0.043 09 x 1.2 x n)
k x (0.014 336) x 1.2 x n,
Process Engineering Channel

134932
= (0.77 x 0.534 86 + 0.04309) x
0.0466
= 1317.27 W/(m ■ C) 2 0

Evaluation of /i,:
np = 28

a, = 28 x (0.014 8336)2
@ProcessEng

a, = 4.84 x lO-3 m2

m 9000/3600
G, = — = — = 516.53 kg/(m- ■ s)
a, 4.84 xl O"3
 Process Design of Heat Exchangers 267

516.53 ,
u, = — = = nAno
0.608 m/s,
p 850

0.014 8336x516.53
Re = t = 12 877.3
0.595 xl0"3

Q 1159
h: = 0.023 x - x (12 877.3)a8(12.8343)0-33
0.0148 336
= 809.445 W/(m2 • 0C)
Overall coefficient based on inside heat transfer area

1
+ = + -i-+ 1
Ui h'fl hi hid 1317.27 809.445 5000

U; = 455.67 W/(m2 • 0C)

</>, 375x1000 ,
Aircn = = = 5.1 m
'cq U:AT.„ 455.67x161.396
2
Heat transfer area per one bank = mljL x rip = 1.5658 m

Number of banks required = ——— = 3.2571

1.5658

n
t
Let number of banks = 4 = —
n
P

(4-3.2571)
% Excess heat transfer area = x 100 = 22.8 %
3.2571
Total number of finned tubes /t, = 28 x 4 = 112
Tube OD = 19.05 mm
Fin OD = 38 mm
No. of fins per inch = 8
Thickness of fin = 0.889 mm
Type of fin = spiral wound transverse fin
Tube length = 1200 mm
Process Engineering Channel

Width of air facing area =1210 mm

Tube pitch = 43 mm (equilateral triangular)
Total inside heat transfer area, A,- = 6.263 m2 (provided)
Total fin area Ay = 71.885 m2
Total bare tube area, A'n = 5.7913 m2
Air side Pressure Drop
@ProcessEng

Net free volume = WLx' - n x — L- n x — (Fin OD2 - c/2) triirL (6.83 b)

= 1.21 x 1.2x0.037 239-28 x ^ (0.019 05)2x 1.2-28

x - (0.0382 - 0.019 052) x 0.889 x 10-3 x 8 x = 0.0365 m3

4 25.4
 Introduction to Process Engineering and Design

4 x net free volume 4 x 0.0365

D
eV = (6.83 a)
28
(71.885 +5.7913) x
(Af + A(' )- 112
n,

= 0.007 518 m
Reynolds number for calculating pressure drop
DevGs 0.007 518x20.941
Re =
R 2000x10"
= 7871.7
Friction factor for calculating pressure drop
/= 1.085 58 x /fe-0-128 025 (6.86)
128 025
= 1.085 58 x (7871.7)-°- = 0.344 25
Effective path length for pressure drop

- x' — - 0.037 239 x 112 -0.148 956 m (6.87)

n
p 28

0.4 0.6
_ fGs2Lp Dev
Aps = (6.85)
D
evP . ST J
0.4
0.344 25 x 20.9412 x 0.148956 f 0.007 518
—x X 1 0.6
0.007 518x1.056 0.043
,2 _
= 1410 N/m- = 143.8 mm WC < 350 mm WC (Ap5max)
Tube Side Pressure Drop:
Tube side pressure drop can be calculated by following equation.
/ \—m \
pu-
A/^Af SJfiL/di) + 2.5 (6.27)

Np = No. of tube side passes = 4

For = 128 77.3 Jf = 0.0045 (From Fig. 6.13)
L = 1.2 m, 4 = 0.014 8336 m
Process Engineering Channel

p = 850 kg/m3, u, = 0.608 m/s, = 1

1.2 850x0.608*
Ap, = 4 8X0.0045 x 1 + 2.5 x
V ^ 0.014 8336 ' /
2
= 3401.25 N/m = 3.401 kPa
Calculated pressure drop is well within maximum allowable (68 kPa).
@ProcessEng

Hence to optimize the design, tube side velocity and tube side heat transfer coefficient
can be increased. With special arrangement in header, number of tube side passes can be
doubled.
Let number of tubes per pass = 14

K
a, = 14 x A- (0.014 8336)/ = 2.4194 x I0"3 m2
 Process Design of Heat Exchangers

G, = 1033.3 kg/(m2 ■ s). Re = 25 760.75, u, = 1.2156 m/s

h, = 1409.6 W/(m2 • 0C)
Ui = 599.313 W/(m2 • 0C)

375x1000
A rca = = 3.8769 m2
'cq 599.313x161.396

3.8769 m2
No. of banks required = — = 2.476
1.5658 m2
n,
Let no. of banks = 3 = —
n
P

3-2.476
% Excess area = x 100 = 21.16%
2.476
Total no. of finned tubes n, = 28 x 3 = 84
Tube OD = 19.05 mm. Fin OD = 38 mm, No. of fins per inch = 8
Thickness of fin = 0.889 mm. Type of fin = Spiral wound transverse fin
Tube length = 1200 mm
Width of Air facing area = 1210 mm
Tube pitch = 43 mm (equilateral triangular)
Total fin area, Af = 53.9139 m2
Total bare tube area A'0 = 4.343 47 m2
Number of tubes per pass = 14
Number of tube side passes = 6
Inside heat transfer area provided A, = 4.6974 m2
Air Side Pressure Drop

4 x 0.0365
Dev = — = 0.007 518 m (no change)
(53.9139+ 4.34347) x —
84
Res = 7871.7,/= 0.344 25 (no change)

L=x'—= 0.037 239 x — = 0.111 72 m (Revised)

' np 28
Process Engineering Channel

Revised air side pressure drop

\
( 0.11172
A/?, = 1410 x .2- 1.058 kPa
= 1057.53 N/m-=
0.148 956

= 107.85 mm WC < Apsmax (= 250 mm WC)

Tube Side Pressure Drop (Revised):
@ProcessEng

Np = 6, Re, = 25 760.75 Jf= 0.0038

u, = 1.2156 m/s

1.2 1 850 x 1.2156

^':2
AP, = 6 8 x 0.0038 x x 1 + 2.5 x
v 0.014 8336
AP, = 18 687 N/m,2 =
_ 18.687 kPa < 68 kPa
 Introduction to Process Engineering and Design

2 410
6.10 PLATE HEAT EXCHANGERS

6.10.1 Introduction

The Plate Heat Exchanger (PHE) consists of a frame in which closely spaced
metal plates are clamped between a head and a follower. The plates have circular
holes in a corner and these holes are sealed around by gasket which also attach
over the plate edges. Holes at the corner are known as ports. Typical plate and
gasketed plate heat exchanger is shown in Fig. 6.34.

Top Canying Bar

Cold Fluid Out

Flot Fluid In
3

Movable Fixed
End date End
pack Cover Cold Fluid In
S Cover
c:
OO Hot Fluid
c Out

4*

Bottom Carrying Bar

Compression Bolt
- Hot Fluid
—
Cold Fluid

Fig. 6.34 Plate-and-frame Heat Exchanger. Hot Fluid Flows down between Alternate Plates and
Cold Fluid Flows up between alternate plates.
Process Engineering Channel

Plates are pressed from stainless steel, titanium, Hastelloy C, Incoloy 825,
nickel 200, Monel 400, aluminium brass, tantalum, etc. The thickness of plate
ranges from 0.5 to 3 mm. The gap between the plates is ranging from 1.5 to 5
mm. This gap is maintained by gasket, which is sandwiched between two metal
surfaces. Plate is having corrugated surface. Corrugated surface design strength-
ens the plates, increases the effective heat transfer area and produces turbulance
@ProcessEng

in the fluids flowing through gaps. Plates are easily cleaned and replaced. The
heat transfer area can be readily increased or decreased by adding or removing
plates, respectively. Hot and cold fluids are allowed to flow in alternate channels.
For any one plate, one side corrugated surface is in contact with cold fluid while
the other side of corrugated surface is in contact with hot fluid. Variety of flow
arrangements are possible.
 Process Design of Heat Exchangers

Water out
Water in
Product in

->— Product out

(a) Counter Flow

(b)

T I \
2 3 5 6 7 8 9
Water out Water in
' <-
Product in Product in
Product in
(c) —v— Water out

iiiuir
2 3 4 5 6 7 8
Water in
-<
Product out
Product in
(d)
Water out 1 I i I 1 I i
2345 6 789
Water in
—>—
Product out
Water out Water in
(e) —-<—
Product in Product out
Process Engineering Channel

Fig. 6.35 Various Arrangements of Flow in Plate and Frame Heat Exchangers

Table 6.36 Gasket Materials for PHE

Gasket Material Temperature limit, 0C

Styrene butadine rubber 85
Medium Nitrile rubber 135
@ProcessEng

Butyl rubber 150

Fluorocarbon rubber 175
Compressed asbestos fiber 260

Heat transfer area per plate ranges from 0.03 to 1.5 nr. Height to width ratio
of plate ranges from 2 to 3. The upper limit of standard gasketed PHE is reported
 Introduction to Process Engineering and Design

as 650 m2 of heat transfer surface. Total number of plates of this PHE is 400.
Variety of gasket materials (Table 6.36) are used in plate size of this PHE having
2.8 m height and 1.1m width.

6.10.2 Advantages and Disadvantages of Plate Heat

Exchangers Over Shell and Tube Heat Exchangers

6.10.2.1 Advantages

(a) Plate heat exchanger provides higher heat transfer coefficient as compared
to shell and tube heal exchanger.
(b) Maintenance and cleaning is easier with PHE as compared to shell and
tube heat exchanger.
(c) Fouling resistance is less with PHE.
(d) Minimum driving force required for heat transfer is 10C for PHE. While
the same is 3 to 50C for shell and tube heat exchanger.
(e) PHE are more flexible. It is easy to increase or decrease the heat transfer
area by adding or removing the plates.
(f) With highly viscous liquid, PHE is belter as it can be easily cleaned.

6.10.2.2 Disadvantages

(a) Fixed cost of plate and hence of PHEs is higher. PHEs are not as widely
used as shell and tube heat exchangers.
(b) Gasketed PHE cannot be used if operating pressure is more than 30 bar or
operating temperature is more than 250oC. While for the same case shell
and tube heat exchanger can be used.
(c) Internal leakage or mixing of two fluids is more common with PHE com-
pared to shell and tube heat exchanger.
(d) Liquid containing suspended particles tend to plug the flow area in PHE
easily and so frequent cleaning becomes necessary. In shell and tube heat
exchanger, chocking can be delayed /avoided by keeping higher velocity in
tubes or by selecting bigger size tubes.

6.10.3 Design of Plate Heat Exchanger

General process design steps2,4,14'15 for PHE are same as that for shell and tube
Process Engineering Channel

heat exchanger. Only differences are mentioned as follows:

1. LMTD correction factor (F?) for PHE is determined from the value of number
of transfer units, (NTU).
Ft=/(NTU)

where, NTU = number of transfer units = ^ (6.88)

@ProcessEng

At = Temperature change required in process stream , 0C.

= Logarithmic mean temperature difference , 0C
For series flow, F, can be taken as 0.95. For 1-1 pass and higher passes
(2-2, 3-3, 4-4) curves of F, vs NTU are available (refer Fig. 6.36).
 Process Design of Heat Exchangers 273

1.00

0.95
s-T
■*O
o-'
p-
c 0.90
_o
*-•
o
o
E
o
U \f<>
0.85

0.80
0 2 3 5
NTU
Fig. 6.36 Log Mean Temperature Correction Factor for Plate Heat Exchanger4
(Reproduced with the Permission of Elsevier, UK)

2. If there is no phase change in the fluid, then forced convective heat transfer
coefficient in conduits or plate film coefficient

/ \
h de
a b
— = cRe Pr (6.89)
kf \ Pw /

Reported values of constant and exponents are in the range of

c = 0.15 to 0.4
a = 0.65 to 0.85
b = 0.3 to 0.45
x = 0.05 to 0.2
Typical values are c = 0.26, a = 0.65, b = 0.4, and .* = 0.14
2 0
where, hp - Plate film coefficient, W/(m C)
de = Equivalent diameter, m
d
Process Engineering Channel

e = 2v,
y = Gap between the plates, m
Re = Reynold number = {de Gp) / pi = {de up p)/ p
Gp = Mass velocity of fluid, kg/(m2 ■ s)

= m/Af

m = Mass flow rate of fluid per channel, kg/s

@ProcessEng

Aj= Cross sectional area of channel or gap (i.e. flow area), m"
up = Channel velocity, m/s
3. Fouling coefficients for PHEs are given in Table 6.37. Fouling coefficients
of PHEs are higher than the same for shell and tube heat exchangers.
 274 Introduction to Process Engineering and Design

Table 6.37 Fouling Coefficients for Plate Heat Exchangers

Fluid Fouling coefficient, W/(m2 ■ 0C)

Cooling water 10 000
Steam 100 000
Demineralized water 100 000
Soft water 50 000
Lubricating oil 6000
Light organic solvent 10 000
Process fluids 5000 - 20 000

4. Pressure drop in plate heat exchanger can be calculated by the following

equation
Ap = ApP + Appo (6.90)
where, Ap- Total pressure drop. Pa
A/7p = Conduit or channel pressure drop, Pa
Appo = Port pressure drop, Pa
Pressure drop occurs, when fluid is flowing through conduit or channel
/
T —2
^ pw,
ApD = 87, —^ (6.91)
d,.

where, de = Equivalent diameter for conduit, m

de = 2y = 2 x gap between plate, m
p = Density of fluid, kg/m3
Up = Channel velocity, m/s
Lp = Path length, m
Lp = Plate length x number of passes
Jf = Friction factor = f(Re)
Value of Jj depends on the design of plate used. For the turbulent flow
following approximate equation can be used.
Jf - 0.6 Re'03 (6.92)

Appo = Pressure drop occurs due to the flow of fluid through ports
Process Engineering Channel

^Ppo = 1-3 x N# (6.93a)

where, uh = Velocity of fluid through the holes, m/s

m
(6.93b)
@ProcessEng

P4

Ah - Area of hole = J2, m2

dh = Diameter of hole, m
Np = Number of passes
 Process Design of Heat Exchangers

Example 6.8
25 kg/s of ethanol liquid is to be cooled from 780C to 40oC in gasketed plate heat
exchanger. Operating pressure at inlet of heat exchanger is 2 atm g. Cooling water, avail-
able in plant at 320C, is used as a cooling medium in heat exchanger. Design the suitable
plate heat exchanger.
Solution:
Heat duty, = m CLA t
CL = Specific heat of ethanol liquid at average temperature (590C), kJ/(kg ■ 0C)
= 2.93 kJ/(kg • 0C)
</>, = 25 x 2.93 x (78 - 40) = 2783.5 kW 780C
Let outlet temperature of cooling water = 40oC 40oC

= 2783.5 kW = m w x 4.1868 x (40 - 32) 40oC 320C

mw = Mass flow rate of cooling water

= 83.1 kg/s = 301 m3/h Fig. 6.37
Logarithmic mean temperature difference for the perfect counter current contact

(78-40)-(40-32)
=
—77^—= 19 254 c
- °
•"It
Number of transfer unit (NTU) based on the maximum temperature difference

At 78 - 40
NTU = = = 1.9736 (6.88)
A'rln 19.254° C
For 1 : 1 pass arrangement, from Fig. 6.36
F, = 0.96
= 0.96 x 19.254 = 18.4840C
Assuming overall heat transfer coefficient
U0 = 2000 W/(m2 ■ 0C)
({,, = U0AA%1

t 27 83.5X103 _
A = = = 75.3 nr
U0 ATm 2000x18.484
Process Engineering Channel

Selecting the plate having effective width 0.5 m and effective length 1.5 m.
Effective area of one plate = 1.5 x 0.5 = 0.75 m2
For the first trial calculation
Area provided = 75.3 m2 s nos. of plates x 0.75 m2
No. of plates s 100.4
Let no. of plates =101
Area provided, Apr0 = 101 x 0.75 = 75.75 m2
@ProcessEng

Number of channels per pass = (101 - 1 )/2 = 50

Let gap between successive plate, y = 3 mm
Equivalent diameter de = 2y = 6 mm = 6x10"3 m
Af = Flow area = Cross sectional area of gap
Af = yW = 0.003 x 0.5 = 1.5 x lO"3 m2
 276 Introduction to Process Engineering and Design

Ethanol side heat transfer coefficient

hp de
= cRe" Prb (6.89)
Kp J
Values of c, a, b, and x depend on the plate design

Let c = 0.26, a = 0.65, h = 0.4 and = 1

de
hp- = 0.26 cRe065 Pr0A

deGp
For the flow of ethanol. Re =
P

mE
Mass velocity of ethanol, GPE =
Total gap area

25
— = 333.33 kg/(mz-s)
50x1.5x10

Channel velocity, uPE = GPE/p

p = Density of ethanol at 590C = 775 kg/m3

333.33 .
UpF = =n
0.43 m/s
775

6 x 10"3 x 333.33

0.6 x 10"3 =3333-3

Viscosity of ethanol at 590C, p = 0.6 cP

p =
Pr
k
Thermal conductivity of ethanot at 590C, k = 0.147 W/(m ■ 0C)

2.93 x 0.6 x 10"3 xlO3

Process Engineering Channel

Pr = = 11.96
0.147

hpe=0.26—Re0-65Pr0A
de

Q 147
/i =0.26x ' , x (3333.3)0"65(11.96)04
1 6 x 10
@ProcessEng

hpe = 3350.43 W/(mi2 ■ 0C)

Cooling water side heat transfer coefficient:

m..
Mass velocity of water, GpW =
Total gap area
 Process Design of Heat Exchangers

83.1
^ 50x 1.5x 10~3 -1108kg/(m2.s)
Density of water at 360C, p = 993.684 kg/m 3

h =—= 1108 =1.115 m/s

pw
p 993.684

deGp
Reynold number Re =

6 x 10-3 x 1108
Re = ^ , = 9233
0.72x10 3

Viscosity of water at 360C p = 0.72 cP

Prandtl number for water at 360C

CLw n 4.1868 x 0.72 x 10"3 x 10-s

Pr =
k 0.6228
Thermal conductivity of water at 360C, k = 0.6228 W/(m ■ 0C)
Pr = 4.84

hpw=026^-Re0b5Pr0A

0.26x0.6228
hpw = — x (9233)0-65 x (4.84)°
6x10

hpw = 19 168.66 W/(mt2 • 0C)

Overall heat transfer coefficient:

J-=-L + -L+^ + -L+-L

U hp hf kn hn hr
'e JE P Pw JW
hpe = 3350.43 W/(m2 ■ 0C)
hje = Fouling coefficient for ethanol = 10 000 W/(m2 • 0C) (from Table 6.37)
tp = Plate thickness = 1 mm = 0.001 m
Process Engineering Channel

kp = Thermal conductivity of plate material

Let the plate material be titanium.
kp = 2\ W/(m • 0C)
hpw = 19 168.66 W/(m2 • 0C)
= Fouling coefficient for cooling water in PHE
= 10 000W/(m2 • 0C) (From Table 6.37)
@ProcessEng

1 1 . + —1— + MIL + 1 +. i
U 3350.43 10 000 21 19168.66 10 000
f/= 1671.52 W/(m2 • 0C)
 278 Introduction to Process Engineering and Design

(p, 2783.5x1000
Area required = = = 90 nr
UATm 1671.52x18.484

Area required > Area provided

For the second trial calculations
No. of plates 121 with 2-2 pass arrangement

121-1
No. of channels per pass = ~ ~ = 30
^X
Area provided, 4pro = 121 x 0.75 = 90.75 m2
For NTU = 1.9736 F, = 0.95 (From Fig. 6.36)
ATm = 0.95 x 19.254 C = 18.2913 0C
0

hpE:

x =
Mass velocity. Gpe = 333.33 ^ 555.55 kg/(m- • s)

x =
Channel velocity, upe = 0.43 " 0.7167 m/s

deGpE 6 x lO-3 x 555.55

Re
= ~= 0.6 X10-3 = 5555 5
-
-NO-65
hDe = 3350.43 x = 4669.84 W/(m2 • 0C)
pe
' v 3333.3
fw
5 _
Mass velocity, Gpw = 1108 x — I O/IA
= 1846.67 kg/(m ■ s)

Channel velocity, upw = 1.115 x ^ = 18583 m/s

Re = 9233.33 x - = 15 389
3
n0 65
15 389 -
hpw = 19 168.66 x = 26 717.5 W/(m2-0C)
Process Engineering Channel

9233.33
Overall coefficient

, —l-— + —1— + Mli + —I— + —L

^7 " 4669.84 10000 21 26717.5 10000

U = 2003.25 W/(m2 ■ 0C)

@ProcessEng

(p, 2783.5x1000 ,
Area required. A,,,,,. = = = 75.9646 m
q
U AT,,, 2003.25x18.2913

Area provided, Apro = 90.75 m

Excess area = I — 1 I x 100 = 19.46% (acceptable)

75.9646
 Process Design of Heat Exchangers

Pressure drops
Ethanol side pressure drop
A/? = App + Appo (6.90)
Channel pressure drop
/ r \ 2
I Lp_ n ]pup
app=m (6.91)
1\ d~ei j <-
Jf=Q.6ReA)3 (6.92)
03
= 0.6(5555.5)- - = 0.045 158
Path length, Lp = Plate length x No. of passes = 1.5 x 2 = 3 m

f 3 \ 775 x 0.71672
An,, = 8 x 0.045 158 x —^ x
' V 0.006 J 2
= 35 953.5 N/nr = 35.954 kPa
Let port diameter (hole diameter) = 120 mm

Hole area = W ().122 = 0.011 31 m2

iih = velocity of ethanol through hole (port)

= W = 25
Uh
pAh 775x0.01131
= 2.8522 m/s
Port pressure drop

pur
= x
APpo 1 Np

775 x 2.85222
= 1.3 x x 2 = 8196 N/m =8.196 kPa
2
Ethanol side pressure drop
Ap = 35.954 + 8.196 = 44.15 kPa
It may be noted that port pressure drop is 18.6 % of total pressure drop which is signifi-
cant.
Process Engineering Channel

Cooling water side pressure drop

' Re = 15 389
Jf - 0.6 to-0 3 = 0.6 x (15 389)"0-3 = 0.033 265
Lf - Plate length x No. of passes = 1.5 x 2 = 3 m
Channel pressure drop

pu\
@ProcessEng

Ap,, = 8/ (6.91)
V J

( 3 \ 993.684 xl.85832
= 8 x 0.033 265 x —^ x
V 0.006 7 2
= 228 295.6 N/m2 = 228.296 kPa (very high)
 Introduction to Process Engineering and Design

Trial-2:
To decrease the cooling water side pressure drop, let number of cooling water side passes
= 1 i.e. 2 : 1 arrangement. Ethanol side heat transfer coefficient, velocity and pressure
drop are same as that for the previous case (2-2 arrangement).
For 2 : 1 arrangement
up = 0.7167 m/s, hpe = 4669.84 W/(m2 ■ 0C), Ap = 44.15 kPa (ethanol side)
For cooling water.
No. of plates =121, No. of passes = 1
For the flow of water,

121-1
No. of channels per pass = —-— = 60

Mass velocity, Gpw = = 923.33 kg/(m2 • s)

2

1 8583
Velocity of water through channel, up = ^ = 0.929 m/s

15 389
Re = = 7694.5

/ \0.65
hpw = 26 717.5 x I ^-1 = 17 026.54 W/(m2 ■ 0C)

Overall heat transfer coefficient

I 1
+
U 2003.25 17 026.54 ~ 26717.5

(/= 1921.26 W(m2 ■ 0C)

<pr 2783.5x1000
Area required Arcq = mL26x^29{3 = 79.206 m2

% Excess area = ( 9Q'75 -1 | x 100 = 14.575%

v 79.206 J
Cooling water side pressure drop:
Process Engineering Channel

Re = 7694.5
y/= 0.6 Re-03 = 0.6 x (7694.5)-0-3 = 0.040 95
Channel pressure drop
/
l ^ —2
pu,
App = SJf X (6.91)
v de j
@ProcessEng

Path length Lp = Plate length x No. of passes = 1.5 m

1.5 y 993.684 x().9292

App = 8 x 0.040 95 x | \ x
04)06
= 35 118.3 N/m2 = 35.118 kPa
 Process Design of Heat Exchangers

Hole or port diameter = 120 mm

Hole area = 0.011 31 m2
uh = Velocity of water through hole (port)

W 83 1
uh = = — = 7.3942 m/s (high)
pA,, 993.684x0.01131
Increase the port size to 150 mm.

m
W .v 83.1 . ,
uh= = = =4.732 m/s
A A 2
P h P h 993.684 x-( 0.15 )
4

PwJ 993.684 X4.7322

Apnl = —- x Nn= 1.3 x = 14462.7 N/m2 = 14.463 kPa
2 2
Pressure drop for the flow of cooling water Ap = 35.118 kPa + 14.463 kPa = 49.58 kPa
Here also, port pressure drop is 29.2% of total pressurre drop.

6.1 I SPIRAL FLOW HEAT EXCHANGERS

6.1 I.I Introduction

Spiral flow heat exchangers provide a spiral flow path for one or both (cold and
hot) fluids being handled. They are of two types; (i) spiral tube exchanger and (ii)
spiral-plate exchanger. These heat exchangers offer the following advantages
over conventional shell and tube heat exchangers.
(a) Compactness.
(b) Centrifugal force increases the heat transfer coefficient particularly of highly
viscous liquid slurries or sludges.
(c) Spiral plate heat exchangers foul at much lower rate than the shell and tube
heat exchanger because of the single flow passage and curved flow path
which does not allow easy settlement of solids.
(d) Relative ease of cleaning.
(e) Spiral configuration reduces stress associated with differential thermal ex-
pansion.
Process Engineering Channel

(f) Maintanance cost is less.

Disadvantages of spiral-tube and spiral-plate heat exchangers over shell and
tube heat exchangers are as follows.
(a) Spiral flow heat exchangers are more expensive (requires higher fixed cost)
than shell and tube heat exchangers having the same heat transfer surface.
(b) Design of spiral flow heat exchangers is not well established like the same
@ProcessEng

of shell and tube heat exchanger.

(c) Pressure drop (loss) is higher than the same in shell and tube heat exchanger.
(d) Maximum design pressure for spiral plate heat exchanger is 10 bar g as the
spiral construction limits the design pressure.
(e) Gasket is special and assembly requires skill.
 Introduction to Process Engineering and Design

6.1 1.2 Spiral Plate Heat Exchanger

Spiral plate heat exchanger is fabricated from two relatively long strips of plate
which are spaced apart and wound around an open split center to form a pair of
concentric spiral passages. Spacing is maintained uniformly along the length of
the spiral by spacer studs welded to plate. Commonly used material for the fabri-
cation of spiral plate heat exchanger are carbon steel, stainless still. Hastelloys,
nickel and nickel alloys, titanium, copper-alloys, etc.
Figure 6.38 shows spiral flow in both channels. Flow channels are closed by
welding alternate channels at both sides of spiral plate.

Fluid - II

Fluid - II

Fluid -1

Fluid -1
Fig. 6.38 Spiral Flow in Both Channels

Figure 6.39 shows flow is spiral in one channel, axial in other. One channel is
completely open on both ends and other closed at both sides of plate.

Steam In
Process Engineering Channel

Cooling Watt
@ProcessEng

Cooling Water In

an-condensables
Condensate Out
Fig. 6.39 Spiral Flow in One Channel, Axial in Another
 Process Design of Heat Exchangers

In spiral plate heat exchangers following three types of flow arrangements are
possible.
A. Spiral flow in both channels (as shown in Fig. 6.38)
B. Spiral flow in one channel and axial flow in other (as shown in Fig. 6.39)
C. Combination flow (as shown in Fig. 6.40)

Cooling Water Out

Steam In

Cooling Water In

Non-eondensables

Condensate Out
Fig. 6.40 Combination Flow

A. Spiral Flow in Both Channels

This type of flow arrangement is used for liquid-to-liquid services. With this type
of flow arrangement spiral plate heat exchanger is covered by flat heads on both
sides. In this arrangement usually two liquids flow counter currently with the
cold liquid entering at the periphery and flowing toward the core and the hot
liquid entering at the core and flowing toward the periphery. Use of this type
spiral heat exchanger is common in cooling hot hydrogenated edible oil from
Process Engineering Channel

deodorizer as it offers good heat transfer coefficient for viscous oil.

B. Spiral Flow in One Channel and Axial Flow in Other

This type of flow arrangement is used for condensing or boiling. With this type
of flow arrangement spiral flow heat exchanger is covered by conical heads on
one or both sides. Condensation or boiling takes place in axial direction. This
arrangement is preferred where there is a large difference in the volumes of two
@ProcessEng

fluids. In case of condensation, diffrence between volumetric flow rates of con-

densing vapour and cooling medium is always large. In case of boiling, if hot oil
is used as heating medium, then also the difference between volumetric flow rate
of boiling liquid and the same of hot oil is large.
 Introduction to Process Engineering and Design

C. Combination Flow
Combination flow is used to condense vapours. In this arrangement condensing
vapour flows axially and then condensate flows spirally. This arrangement is
used for condensation with subcooling. Part of the open spiral is kept closed at
the top. Entering fluid (condensing vapour) flows axially through the center part
of assembly in downward direction. Condensate at bottom flow spirally and com-
ing out from the side bottom. With this arrangement spiral heal exchanger is
equipped with conical head at top and flat cover at bottom.

6.1 1.3 Process Design Steps for Spiral Plate Heat

Exchanger

General process design steps15,16 are as follows:

(i) Calculate heat duty
(ii) Select cooling medium or heating medium
(iii) Based on energy balance calculate the mass flow rate of heating medium or
cooling medium.
(iv) Calculate the LMTD.
(v) Assume the value of overall heat transfer coefficient for the first trial calcu-
lation.
(vi) Determine the heat transfer area required based on the assumed value of
overall heat transfer coefficient.

0/
A = = Heat transfer area provided for the lirst trial calculation
x
^
(vii) Heat transfer area for spiral plate heat exchanger
A = 2xLxH (6.94)
where, A = Heat transfer area, m
L = Length of plate, m
H = Width of plate = Height or length of heat exchanger, m
Fix the value of H and find the value of L

L = ——— (6.95)
2xH
Process Engineering Channel

Diameter of heat exchanger or diameter of outside spiral can be calculated

by following equation.
Ds = [1.28 x L{dc + dh + 2t) + c2)m (6.96)
where, Ds = Outside spiral diameter, m
L = Length of plate, m
dc = Channel spacing of cold side, m
@ProcessEng

dh = Channel spacing of hot side, m

t = Plate thickness, m
c = Core diameter, m
Some dimensions of spiral plate heat exchanger are standardized and are as
follows.
 Process Design of Heat Exchangers

1. Plate width// : 101.6 mm (4 in), 152.4 mm (6 in),

304.8 mm (12 in), 457.2 mm (18 in),
609.6 mm (24 in), 762 mm (30 in)
914.4 mm (36 in), 1219.2 mm (48 in),
1524 mm (60 in) 1778 mm (72 in)
2. Core Diameter, C 203.2 mm (8 in), 304.8 mm (12 in)
3. Channel spacing, dc and dh 4.76 mm (3/16 in) (for 304.8 mm maxi-
mum width)
6.35 mm (1/4 in) (for 1219.2 mm maxi-
mum width)
7.94 mm (5/16 in), 9.525 mm (3/8 in),
12.7 mm (1/2 in), 19.05 mm (3/4 in),
25.4 mm (1 in)
4. Plate thickness, t For carbon steel 3.175 mm (1/8 in),
4.76 m (3/16 in),
6.35 mm (1/4 in), 7.94 mm (5/16 in)
For stainless steel 14 to 3 US gauge
In spiral plate heat exchanger to arrive at the best compact design outside diam-
eter of spiral Ds and plate width (H) are kept approximately equal.
(viii) Calculate the equivalent diameter of flow channel by following equation.

4 x flow area 4[spacing x width]

D =
wetted perimeter 2(spacing x width)

For hot fluid

4xidh x H)
/9„,. = (6.97)
2{dh + H)

For cold fluid

4x(d(. xH)
D
ec = (6.98)
2{dc + H)

(ix) Calculate the Reynolds number by following equation.

Process Engineering Channel

2m
Re = (6.99)
Hxn

where, m = Mass flow rate of fluid, kg/s

H = Width of plate, m
/u = Viscosity of fluid, kg/(m • s)
Reynolds number is calculated for both; cold fluid and hot fluid,
@ProcessEng

(x) Calculate the critical Reynolds number Rec. Critical Reynolds number is
the value of Reynolds number above which turbulent flow is achieved.

'V0-32
Re= 20 000 (6.100)
v Ds
 Introduction to Process Engineering and Design

where, Rec = Critical Reynolds number

De = Equivalent diameter of flow channel, m
Ds = Outside diameter of spiral, m
(xi) Calculate the cold fluid side and hot fluid side heat transfer coefficients by
using the suitable correlations. Various correlations for calculating heat trans-
fer coefficient for spiral plate heat exchangers are given as follows,
(a) For spiral flow with no phase change and Re > Rec (i.e. turbulent flow):

h
1+3.51 (0.023 Re~0 2 x Pr-273) (6.101)
CpG Ay

For spiral flow with, no phase change and. Re < Rec (i.e. laminar flow)

, \-O.I4
1/6 (
Vf
= 1.86 Re~2n Pr~2'3 (— (6.102)
CpG [D, Vb

where, h = Heat transfer coefficient, W/(m*" • 0C)

Cp = Specific heat of fluid, J/(kg • 0C)
G = Mass velocity of fluid, kg/(m • s)
Re = Reynolds number

CpH
Pr = Prandtl number = —-—
k
/J = Viscosity of fluid, kg/(m - s)
k = Thermal conductivity of fluid, W/(m • 0C)
d = Channel spacing, dc or d^ m
Ds = Outside spiral diameter, m
Here mass velocity is calculated by following equation

G = —-— (6.103)
{dxH)
Process Engineering Channel

where, m = Mass flow rate, kg/s

d = dc or dh, m
H - Width of plate, m
(c) For axial flow with, no phase change and, /?c > 10 000

—= 0.023 Re'02 Pr2'3 (6.104)

@ProcessEng

CpG

(xii) Calculate the overall heat transfer coefficient by following equation.

^- = — + —+ — + — + — (6.105)
U hc hh hcd hhd km
 Process Design of Heat Exchangers

where, U = Overall heat transfer coefficient, W/(nr ■ 0C)

hc = Cold fluid side heat transfer coefficient, W/(m ■ 0C)
hh = Hot fluid side heat transfer coefficient, W/(m2 • 0C)
hcd = Cold fluid side fouling coefficient, W/(m2 ■ 0C)
hhd = Hot fluid side fouling coefficient, W/(m2 • 0C)
t = Thickness of plate, m
kin = Thermal conductivity of plate material, W/(m • 0C)
(xiii) Calculate the heat transfer area required

A = ——— (6.106)
UAT]n

(xiv) Calculate the % excess heat transfer area. Ideally it should be in between
10 to 20%.
(xv) Calculate the cold fluid side and hot fluid side pressure drops by using the
suitable correlations. Various correlations for calculating pressure drop for
spiral flow heat exchanger are given as follows.
(a) Spiral flow with no phase change and Re > RecC

2 1/3
w 1.3 p1/3
Ap= 0.0789- fH] + 1.5 + — (6.107)
P dsH (ds + 0.0032) kw) L

(b) Spiral flow with no phase change and 100 < /?<? < Rec

L 1.0351/2 16
Ap = 36.84 + 1.5 +
dsH + 0.0032) yWy Ph

(6.108)
(c) Spiral flow with no phase change and Re < 100

r if ^0-17
Pf
Ap = 5.5256 x 10 (6.109)
2.75 H
d Ph

(d) Axial flow with no phase change and. Re > 10 000

Process Engineering Channel

/
W^1'8 /
,0.2 H
Ap = 253.85 0.0115 ir —+ 1 + 0.03// (6.110)
L d.

where, Ap = Pressure drop, Pa

L = Total length of plate, m
p = Density of fluid, kg/m
W = in = Mass flow rate of fluid, kg/s
@ProcessEng

ds = Channel spacing (dc. or dh), m

H - Width of plate, m
p = Viscosity of fluid, kg / (m • s)
pb = Bulk fluid viscosity, kg/(m • s)
Calculated pressure drop must be less than or equal to maximum allowable
pressure drop or optimum pressure drop.
 Introduction to Process Engineering and Design

Exampel 6.9
Design a spiral flow plate heat exchanger for cooling the malamine suspension liquid
from 470C to 330C by using cooling water as cooling medium based on the following
data. Cooling water is available at 320C.
Data
(i) Composition and flow rate of melamine suspension liquid

Table 6.38

Component kg/h mole % mass %

Water 16 052 74.2 57.21
Carbon dioxide 3151 5.49 11.23
Ammonia 3055 14.96 10.89
Urea 1329 1.84 4.74
Melamine 4470 2.95 15.93
Total 28 057 100 100

(ii) Physical properties of melamine suspension liquid

(a) Specific heat C, = 3.349 kJ/(kg ■ 0C)
(b) Thermal conductivity k = 0.4935 W/(m • 0C)
(c) Viscosity
At 470C, ii= 1.8 cP
0
At 33 C, n = 2.3 cP
(d) Density
At 470C, p = 1120 kg/m3
At 330C, p= 1126 kg/m3
(hi) Suitable material of construction: SA: 240 Gr 316 L
(iv) Maximum allowable pressure drops
For malamine suspension liquid = 1.5 bar
For cooling water = 1 bar
Solution:
Heat duty

d, = the, At = f 28 057 x —1 x 3.349 x (47 - 33)

Process Engineering Channel

' I 3600 7
= 365.41 kW
Mass flow rate of cooling water:
Energy balance
m
<P, = w CLw At = mw x 4.1868 x (36 - 32)
For the first trial calculations let the outlet temperacture of cooling water = 360C
@ProcessEng

• = 365.41 = 21 819 ^ 78 55 m3/h

H
4.1868x4
 Process Design of Heat Exchangers 289

LMTD
470C
(47-36)-(33-32)

' 47-36' 360C

In 330C
33-32 320C

A'4 =4.170C
Fig. 6.41
Assuming the value of overall heat transfer
coefficient
U0 = 1500 W/(m2 • 0C)
Heat transfer area

365.41x1000
A = = 58.42 m2
UAT,,, 1500x4.17

Heat transfer area provided for the first trial calculations

A = 58.42 m2 =2xLxH (6.94)
Let H = 24m = 0.6096 m

58.42
L= = 47.9167 m
2 x 0.6096

To get the best compact design of spiral plate heat exchanger, width of plate (or length of
heat exchanger) should be approximately equal to outside spiral diameter (or outside
diameter of heat exchanger.)
Let other diamensions of heat exchanger:
dc = Channel spacing for cold side fluid = 12.7 mm
dh = Channel spacing for hot side fluid = 6.35 mm
c = Core diameter = 203.2 mm
t - Plate thickness = 3.175 mm
Outside spiral diameter
Ds = [l.28 x L{dc + dh + 2t) + c2]1/2 (6.96)
= [1.28 x 47.9167(0.0127 + 0.006 35 + 2 x 0.003 175) + 0.20322]1'2
= 1.2646 m
Process Engineering Channel

H*DS
For second trial calculations let // = 36 in = 914.4 mm
L = 31.944 m
D, = [1.28 x 31.944(0.0127 + 0.006 35 + 2 x 0.003 175) + 0.203222-|l/2
]
= 1.04 m
H = DS
@ProcessEng

H = 914.4 mm, Ds = 1040 mm, L = 31.944 mm

dc = 12.7 mm, dh = 6.35 mm, C = 203.2 mm
t = 3.175 mm
Note: These dimensions of heat exchanger are not the final dimensions. These can be
changed after heat transfer coefficient calculations and/or pressure drop calculations.
 Introduction to Process Engineering and Design

Hot fluid side heat transfer coefficient calculations:

Equivalent diameter

Ax{dhxH)
D
eh - (6.97)
2(dh+H)

4 x (6.35x914.4)
Deh = = 12.6 mm
2(6.35+914.4)
Reynolds number.

2m
Re = (6.99)
H xn

1.8 + 2.3
i"a- = 2.05 cP

2x7.7936
Re = = 8315.3
0.9144x2.05x10 -3

Critical Reynolds number,

>0.32
D.
fll6f2
Re,. = 20 000 = 20 000
D 11040J

= 4871.9
Re > Rec i.e. process fluid will flow in turbulent region
For spiral flow with, no phase change and Re > Rec

hi.
r Deh ^
1 + 3.5 (0.023 for0-2 x pr2'3) (6.101)
cpG
I ^ JJ

Cp = 3.349 kJ/(kg • 0C)

CPP
Prandtl number. Pr =
Process Engineering Channel

3.349 x ^-x( 2.05 xlO-3)

1
0.4935
= 13.912

m 7.7936
Mass velocity, G =
dhxH 0.006 35x0.9144
@ProcessEng

= 1342.234 kg/(m2 • s)

h .(12.6
- 1+3.5 x 0.023 x 8315.3-0-2 x 13.912-273
3.349 x 10 x 1342.234 1040
 Process Design of Heat Exchangers 291

hh = 3063.9 W/(m ■ s)
Cold fluid side heat transfer coefficient calculations

4x (dc. x //)
D.. = (6.98)
2{dc + H)

4 x (12.7x914.4)
= 25.052 mm
2(12.7+914.4)
Reynolds number.

2m 2x21.819
Re = (6.99)
0.9144 x 0.738 x 10~3

(Viscosity of water at 340C = 0.738 cP)

Re = 64 665.44
Critical Reynolds number,
N0.32 0.32
De^ 052
Rec = 20 000 = 20 000 I ——
Ds /
V 1040

= 6070.28
Re > Rec
For spiral flow with, no phase change, and Re > Rec.

h,. ' Dec ^

1 + 3.5 (0.023 Re-0 2 Pr~2/3) (6.101)
C G D
P \ s> /
C„ = 4186.8 J/(kg • 0C)

m 21.819
Mass velocity G =
dcxH 0.0127x0.9144

= 1878.9 kg/(m2-s)

Cp*p 4186.8 x 0.738 xlO-3

Prandtl number. Pr =
k 0.62
(Thermal conductivity of water at 34 C k = 0.62 W/(m ■ k))
0
Process Engineering Channel

Pr = 4.9836

K (
25.052
= 1 + 3.5 x 0.023 x 64665.44_0-2 x 4.9836-2/3
4186.8x1878.9 1040
hc = 7336.76 W/(m2 • 0C)
Overall heat transfer coefficient
@ProcessEng

1
•+ (6.105)
U h. h,, h,. K k„

where, hc = 7336.76 W/(m2 ■ 0C), hh = 3063.9 (m2 ■ 0C),

hcd = 15 000 W/(m2 • 0C), hh =\ 5 000 W/(m2 • 0C),

 Introduction to Process Engineering and Design

/ = 0.003 175 m
k = 16.26 W/(m • 0C) (of stainless steel)

_l_ ] + 1 + 1 + 1 + 0.003175
U 7336.76 3063.9 15 000 15 000 16.26

U = 1263.78 W/(in2 • 0C)

0,
Heat transfer area required, A,. =
UA%In

365.41x1000
A, = = 69.34 m2
1263.78x4.17
Required area, Ar > Area provided, Api. which is not acceptable.
For the second trial calculations let L = 42 m

69.34x1.1
L=
2xH

Area provided Ap - 2 x L x H
A =2x42x0.9144 = 76.81 m2
Revised value of Ds (outside diameter of spiral)
Ds = [1.28 x L(dc + dh + 2t) + t'2]1/2
= [1.28 x 42(0.0127 + 0.006 35 + 2 x 0.003 175) + 0.20322]1'2
= 1.186 m
Critical Reynolds number for hot fluid
\0.32
12.6
Re. = 20 000 = 4671.34
1186
Re > Rec
Revised value of hot fluid side heat transfer coefficient

12.6
1+3.5
1186
K = x 3063.9
1+3.5
i—1
v1040 /
Process Engineering Channel

hh = 3048.56 W/(m2 • 0C)

Critical Reynolds number for cold fluid
0.32
052
Re. = 20 000 = 5820.4
V 1186
Re > Re.
@ProcessEng

Revised value of cold fluid side heat transfer coefficient

25.052^
1+3.5
1186 I,
h.C = / x 7336.76 = 7266.53 W/(m2 • 0C)
25.052
1 + 3.5
1040
 Process Design of Heat Exchangers 293

Overall heat transfer coefficient

1 _ 1 1 I I 0.003175
■+■ • + —-— + —-— + ■
U 3048.56 7266.53 15000 15000 16.26
U= 1259.07 W/(m2 • 0C)
Heat transfer area required

365.41x1000
A,. = = 69.6 m2
1259.07x4.17
Area provided. A =76.81 m2 > A= 69.6 m2

76.81-69.6
Excess heat transfer area = x 100 = 10.36% (acceptable)
69.6
Malamine suspension liquid side pressure drop:

1/3
L iV/3 r/n 16
A/) = 0.0789 + 1.5 + (6.107)
d/H (ds+0.0032){ W J L

L = 42 m, p = 1123 kg/m3, W= 7.7936 kg/s

ds = dh = 0.006 35 m, H = 0.9144 m
p = 2.05 x lO-3 kg/(m • s)
-i2
42 7.7936
Ap = 0.0789 x
1123 0.006 35x0.9144

1/3
1.3(2.05 X10~3)I/3 0.9144
x 1.5+ —
0.006 35 + 0.0032 V 7.7936 7 42

= 55 004.5 Pa = 55 kPa = 0.55 bar < 1 bar (Acceptable)

Cooling water side pressure drop

1/3
W l-3pl/3 (h
Ap = 0.0789 - + 1.5 + 1* (6.107)
P ydsHy {ds+0.m2)\W L

L = 42 m, p = 1000 kg/m3, W = 21.819 kg/s

ds = dc = 0.0127 m, H= 0.9144 m, p = 0.738 x 10"3 kg/(m • s)
Process Engineering Channel

42 21.819
A/j = 0.0789 x
1000 0.0127x0.9144

,1/3 ,
1.3x(0.7378xl0-3)"3 |-oi9i44y-- , 16
1 5

(0.0127+0.0032) I2I.8I9J " 42

@ProcessEng

= 52 023.5 Pa = 0.52 bar < 1 bar

Comments: In the given case, malamine suspension liquid solution is a slurry solu-
tion. Hence, spiral plate heat exchanger is better choice as compared to shell and tube
heat exchanger because of the following reasons.
(i) Slurry solution must be allocated to shell side of shell and tube heat exchanger to
facilitate the ease of flow. Shell and tube heat exchanger must be U-tube or floating
 Introduction to Process Engineering and Design

head heat exchanger to facilitate removal of tube bundle and the frequent cleaning.
Also, malamine solution required the use of special material, SS: 316 L. Hence,
shell, tubes, tube sheets, baffles, floating head and/or one of the heads must be of
SS 316 L.
(ii) Shell and tube heat exchanger provides less heat transfer coefficient for the slurry
solution as compared to spiral plate heat exchanger.
Also, fouling coefficients are lesser with shell and tube heat exchanger compared
to spiral plate heat exchanger. Hence shell and tube heat exchanger requires more
heat transfer area.
(iii) Cleaning is easier with spiral plate heat exchanger but requires skill.
(iv) Because of the compactness spiral plate heat exchanger will occupy less space as
compared to shell and tube heat exchanger.
(v) Here cooling water is available at 320C. It can cool the malamine solution upto
330C with spiral plate heat exchanger design, wherein driving force is only 10C.
Minimum driving force required for heat transfer in shell and tube heat exchanger
is 30C.
Based on (i) and (ii) it can be concluded that the cost difference between spiral plate
heat exchanger and shell and tube heat exchanger is less.

6.12 BRAZED ALUMINIUM PLATE-FIN HEAT

EXCHANGER

Typical brazed aluminium plate-fin heat exchanger handling multiple streams is

shown in Fig. 6.42. This type of heat exchanger is prefered for low temperature
(sub zero temperature) cryogenic applications as it offers the following advan-
tages.

Header
Out:

Distributor Fin
Wear Plate
Heat Transfer Fin
Process Engineering Channel

Spacer Bar
Parting Sheet

Support Plate
@ProcessEng

Cap Sheet
i liiPn

Fig. 6.42 Brazed Aluminium Plate-fin Heat Exchanger17

 Process Design of Heat Exchangers

(a) It can handle temperature approaches down to less than 20C. In cryogenic
duties operating cost is dominated by the cost of energy required to gener-
ate the low temperatures; hence such close temperature approach is very
important.
(b) It is the most compact and lightest heat exchanger and it provides the maxi-
mum heat transfer area density.
(c) It can operate with a thermal effectiveness up to 98%.
(d) It has multistream capability. All cold streams produced in process can be
passed through single heat exchanger to cool the incoming warm streams.
(e) It is an expensive heat exchanger.

6.12.1 Construction and Working

It consists of alternating layers of plates and corrugated fins. Flow passes are
formed between the consecutive plates (plates are known as parting sheets). These
sheets provide the primary surface and fins provide the secondary surface for
heat transfer.
Brazed or corrugated fins hold the heat exchanger together. At the end of heat
exchanger pads of finning are laid at an angle and serve as distributors, while in
major part of heat exchanger finning are laid parallel to the axis. Streams are
flowing truely in counter current directions. Each stream flows in number of
layers, each of which is divided into numerous parallel, nearly rectangular sub-
channels by the fins. Fin heights and frequencies decide the size of these sub-
channels. Fin heights are in between 5 to 9 mm and fin frequencies in the main
heat transfer region is 590 to 787 fins/m (15 to 20 fins/in). The equivalent hy-
draulic diameters of these subchannels are only a few millimeters. These small
passages result in very high heat transfer area density in the range of 800 to 1500
m2/m3. For comparison, heat transfer area densities of shell and tube heat ex-
changers are about 50 to 250 m /nr and the same of plate and frame heat ex-
changers are about 200 to 1000 nr/m3. Such high area density and with alu-
minium construction make this heat exchanger the smallest as well as the lightest
among all other type of heat exchangers. Typical size of such a heat exchanger
can be 1.2 m wide, 1.2 m deep and 6.2 m long. This heat exchanger can also be
used as vaporizer or condenser.
Process Engineering Channel

Brazed aluminium plate heat exchangers can be used at pressures up to 100

bar and within a temperature range of -2690C to 100oC. With appropriate alloys
for the headers and nozzles, they can be used up to 200oC. However, the maxi-
mum permissible temperautre for aluminium alloys decreases rapidly with in-
creasing pressure.

6.13 HEAT EXCHANGER NETWORKING FOR

@ProcessEng

ENERGY INTEGRATION

Energy requirement of a chemical plant can be considerably reduced by process

integration. For example, in acetaldehyde plant, exothermicity of the reaction
(e.g. partial oxidation of ethanol) is utilized as a part of heat duty required by the
reboiler of the distillation column of the same plant. This integration reduces
 Introduction to Process Engineering and Design

saturated steam required for the reboiler of distillation column and eliminates the
requirement of cooling medium for the reactor. Large scale chemical plant uses
large number of heat exchangers. These heat exchanges are either heaters and
vaporizers or coolers and condensers. Integration between few of them reduces
hot utility requirement (e.g. requirement of saturated steam) as well as cold util-
ity requirement, (e.g. requirement of cooling water). Systematic method is devel-
1Q
oped by Linnhoff and others for the energy integration via systematic heat
exchanger networking which is known as pinch technology.
In heat exchanger networking via pinch technology, following facts are con-
sidered.
1. The heat transferred from a hot stream must be equal to heat transferred
from cold stream (heat losses are neglected).
2. Heat can only be transferred from a hotter fluid to a colder fluid (second
law of thermodynamics). Therefore, the temperature of a cold fluid must be
less than that of a hot fluid at all points along the path of heat exchanger.
A^(: In actual energy integration temperature of hot stream must be reason-
ably greater than the same of cold stream to get an acceptable rate of heat trans-
fer. This acceptable minimum temperature difference is also called pinch tem-
perature difference. Choice of pinch temperature difference A^in is important.
The lower value of A2^in decreases the energy requirement but increases the
fixed cost of heat exchangers. Minimum suggested value of A^^ is 10oC. This
implies that in any of the exchangers to be used in the network, the temperature
difference between the hot stream and cold stream will not be less than 10oC. For
any network, there will be a best value for the minimum temperature difference
(A^lin) that will give the lowest total annual operating cost. It is usually in be-
tween 10oC to 20oC.
"Hot streams" and "Cold streams": For heat exchanger networking total streams
considered are divided in to two types. "Hot streams" are the streams that need
cooling (heat sources) while "Cold streams" are the streams that need heating
(heat sinks).

6.13.1 Representation of Heat Exchanger Network

Heat exchanger network is represented as a grid. The process streams are drawn
as horizontal lines, with the stream numbers shown in square boxes, as shown in
Process Engineering Channel

Fig. 6.45. Hot streams are drawn at the top of grid and flow from left to right. The
cold streams are drawn at bottom, and flow from right to left.
Coolers and heaters are represented as circles; (C) and (//), respectively. Heat
exchangers which are used to exchange the heat between the two process streams
are marked by two circles and the two circles are connected by vertical line. Two
circles with vertical line connect the two streams between which heal is being
@ProcessEng

exchanged.
As shown in Fig. 6.43, in this case a is hot stream number, n is cold stream
number. A is a heat exchanger exchanging the heat between hot stream a and
cold stream n. Cooler C cooles the stream further after it leaves the heat ex-
changer A. Heater H heats the stream n after it leaves the heat exchanger A.
Calculations for finding minimum utility requirements for the given stream
data:
 Process Design of Heat Exchangers 297

W (£>
Hot Stream Utility HE
(U 1-.
u — as
d > D

Utility HE Cold Stream

Fig. 6.43 Grid Presentation

First step for this is selection of the value of minimum temperature difference,
A^in between hot streams and cold streams. Then for the chosen value of
minimum utility required can be determined by the following method, developed
by Hohmann and Lockhart. This method is illustrated by following example.

Example 6.10
Synthesize the heat exchanger network for the following four process streams such that
resulting heat exchanger network will require the minimum hot and cold utilities. Also,
find the values of minimum utilities (hot and cold) required.

Table 6.39 Process Stream Data

Stream Type '« Cp, kW/0C tm, 0C tout, 0C

1 Hot 10 250 130

2 Hot 8 160 90
3 Cold 7 60 160
4 Cold 6 110 260

Solution:
Select the value of A^ljn = 10oC. (Selected value of A^lin, may not be equal to optimum
temperature difference.) For A'7^B = 10oC, Table 6.40 is prepared by calculations, pre-
sented below.
Method for Preparing the Table:
The hottest temperature in the data is cold stream 4 outlet temperature (260oC). List it
at the top of the cold stream temperature column (column 2). Note down the corre-
Process Engineering Channel

sponding hot stream temperature (270oC), which is 10oC (= A^in) hotter at the top of
the hot stream temperature column. Next highest temperature is of hot stream 1 tempera-
ture; 250oC. Corresponding cold stream temperature based on A^j,, = 10oC is 240oC
and written second in column 2. Similarly, temperatures of hot streams and cold streams
are written in descending order either in column 1 (if it is hot stream temperature) or
in column 2 (if it is cold stream temperature). While corresponding temperatures for
A^^ = 10oC are written in other columns.
@ProcessEng

There are seven temperature intervals in this problem. In column 3 available heat by
hot streams for each temperature interval is calculated. No hot stream is available at
270oC, hence available heat for 7lh interval is zero. Since hot stream temperature of
270oC is of academic interest only and so it is shown in brackets in column 1.
 298 Introduction to Process Engineering and Design

-o "3
On o o o o c c o
OJ CN ON, -+ ON OJ 00
aj "O ^ I CO Ol b" CO N" CN
< U

■o ■a
■o o c o o o O c o
oo Ol o o- CN
CO 0~ c NO
— CN CN CO —1
u

B
■S)
O
D. « o o c O C o O
r-~ so CN (N
CO
CO IO, m cc, "b
u 5
-o c
c
n
tH
a
(/)
C
o
s c3O
— -C o o o o o O O o
g Ol 5 CO Ol
J—H ■OJ NO o
3 NO cfl -vS — NO r- CN •b NOr
,—1 ,—1
VJ 2 c3
3 O
o u

0 o —
OJ ■b «
1 8 ^
"o "O o o c o o o c
<N 00 CO ON, CO — b"
p" p3 S — -t CO rsi —
o S a-
u
IS) U "
v3
o cfl C3
TT £
•O cs o o C o c O
"g o o -+ Ol NO NO
d S -o i oo On •b in O; O;
— o — —T
jO o a
(2 X VI 03
O

B CS
u
'<A -C
O o c o c o c
o c -t 00 -1"
CO i" 00 — m, CN
Process Engineering Channel

i
o
U
l CO

1 H
3 U U u U U U U
b 2
0 o o
o
o
C oU o
O
CN <y) V u O
b" nC o
I/-,
c
O^l
C
oc NO
2 Q. 01 (N
3 £
u <4
@ProcessEng

f- nO ■n CO (NJ —
£
C5 H u u U U U u U
a
o O o o o
H 3 O 0 o o CO O c O
2 u NO, o nC CO CN o^ r-
(U OJ 01 r-
o Q.
£ — 1 Ol 1
X
 Process Design of Heat Exchangers

For 6lh interval (in coloumn 3) available heat is calculated as ('"Cp, (250oC - 170oC)
= 10 (250 - 170) = 800 kW. So, in sixth interval hot stream I is cooled from 250oC to
170oC. Stream 1 is also the only hot stream in interval 5, contributing another 100 kW,
when it cooles from 170oC to 160oC. Interval 4 has both hot streams 1 and 2. In interval
4 both streams are cooled from 160oC to 130oC. Hence available heat for interval 4 is
calculated as follows
[(>nCp)x + (mCp)2] (160oC - 130oC) = ((10 + 8) x 30) = 540 kW
In column 4 casacaded heat available indicates cumulative or total heat available at
temperature t, when hot streams cool from 250oC to temperature fC.
In column 5 required heat by cold streams for each temperature interval is calculated.
Stream 4 is present only in interval 7 and requires 120 kW heat to increase its tempera-
ture from 240oC to 260oC, {mCp\ (260 - 240) = 6(260 - 240) = 120 kW.
In interval 5 both streams 3 and 4 are present. Hence, required heat for interval 5 is
[(mC^ + {{mCp\] (160 - 150) = ((6 + 7) x 10) = 130 kW. Cascaded required heat by
cold streams at different temperatures are shown in column 6.
Column 7 represents the net available heat for each interval.
Net available heat (column 7) of any interval = Heat available with hot streams (col-
umn 3) in this interval - Heat required by cold streams (column 5) in the same interval
Column 8 represents the cascaded net available heat or cumulative net available heat
at the end of each interval, starting from the 7lh interval to lsl interval. Cascaded heat is
the amount of heat available from the hot streams over that required by cold streams at
any temperature t, as one starts the calculation from the highest temperature to the low-
est temperature. Find the highest negative number in column 8. In this example it is
-120 kW. It implies that 120 kW is the minimum amount of heat that must be supplied
from hot utilities. The same amount of heat (120 kW) is added in each number of 8lh
column. This gives 9,h column. The point in the last column where the value of adjusted
cascaded heat is zero is the pinch point. Top number in last column (120 kW), is the
minimum amount of heat that must be supplied from hot utilities and the bottom number
(280 kW) is the minimum amount of heat that must be removed by cold utilities.
Grand Composite Curve (GCC):
It is the most important curve or graph to understand heat exchanger network synthesis
problem. To draw this curve for the given problem, Table 6.40 must be prepared, based
on given data. Then GCC is the plot of adjusted cascaded heat obtained in the last
column (O1'1 coloumn) vs hot stream/cold stream temperatures. (Column I and 2). GCC
Process Engineering Channel

for this example is shown in Fig. 6.44.

In this curve each interval is represented by line segment. Each interval is either con-
suming heat (heat sink) or producing heat (heat source). Interval which acts as a heat
sink, represented by a line segment that moves down and to the left. Interval which acts
as a heat source, represented by a line segment that moves down and to the right. For
example 7th interval locally requires 120 kW of heat input (heat sink), hence it is repre-
sented by line segment which moves downward and to the left. Interval 6 produces 320
@ProcessEng

kW of heat (heat source), hence it is represented by line segment moving downward and
to the right.
Whenever there is a heat source segment just above a heat sink segment right facing
noze appear in the Grand Composite Curve. Such right facing nozes can be self inte-
grated. While the bold segment above the pinch point requires heat from hot utilities and
 Introduction to Process Engineering and Design

120 kW.
270/260

250/240 Pii ich P oint

240/230 <

230/220 \

\
0U 220/210

210/200 \
I-
| 200/190 \

I 190/180 \

\
C3<DS 180/170
\ 7 his p ait o GCC
^ 170/160 c an be selt integ ated
d 150/140 1 <
1
1 130/120 l
1
110/100 1
1
1 \
90/80 1
1
80/70 1
70/60
280 kW
1— —r
0 100 200 300 400 500 600
Cascaded Heat, kW

Fig. 6.44 Grand Composite Curve

bold segment below the pinch up to the dashed line represents the heat which must be
removed by cold utilities.
Heat exchanger network synthesis for the maximum energy recovery:
Network design for the maximum energy recovery and minimum use of hot and cold
utilities can be divided in the following steps.
Process Engineering Channel

(a) Select the value of

(b) Prepare the table (like Table 6.40) for drawing the Grant Composite Curve.
(c) Calculate the minimum hot utility required and the minimum cold utility required.
Identify the pinch point.
(d) For the maximum heat recovery do not use cold utilities above the pinch and do not
use hot utilities below the pinch. Also, do not transfer heat across the pinch.
(e) Estimate the number of exchangers above the pinch equal to IV- 1, where N is the
@ProcessEng

number of streams above the pinch. Similarly estimate the number of exchangers
below the pinch equal to M - 1, where M is the number of streams below the pinch.
(f) Invent a suitable network.
Applying the same steps to the given problem.
(a) A'i^in = 10° C (selected)
 Process Design of Heat Exchangers

(b) GCC is drawn based on the value of (Fig. 6.44).

(c) Minimum hot utility required is to supply 120 kW heat and the minimum cold
utility required is for removing 280 kW heat. Pinch point occurs at 250oC hot stream
temperature and equivalent cold stream temperature of 240oC.
(d) Above the pinch only stream 4 exists. Hot oil (another stream) can be used to in-
crease the temperature of stream 4 from 240oC to 260oC. Thus N = 2 which means
one heat exchanger is needed for this heat duty. Heat duty of this heater is 120 kW.
Below the pinch all four process streams and one cold utility stream exists (M = 5).
Thus there is a need of four exchangers for this part or below the pinch.
(e) One possible heat exchanger network for the maximum energy recovery is shown
in Fig. 6.45.

270oC 260 C

THERMIC FLUID 0= 120kW

250oC 240 C
lb la
0 = 780 kW

2l0oC
I700C 160 C
0 = 140 kW

160°C
150°C

DM WATER ec; — 140 C

]0 = 280 kWl
130oC 120oC
0 = 560 kW

120oC 4 110oC

90oC 80 C
Process Engineering Channel

70oC 60 C
Stream la lb 2 3 4
(«<,» 6.5 3.5 8 7 6
560
@ProcessEng

Total Heat Flow, kW 780 420 700 900

Fig. 6.45 Heat Exchanger Network

Hot stream 1 contains ( fnCp) At = 10 x (250 - 130) = 1200 kW heat. Part of this heat
can be utilized to increase the temperature of stream 4 from 110oC to 240oC by using the
heat exchanger A. Heat duty of heat exchanger A is 6 x (240 - 110) = 780 kW. Stream 1
is divided in two parts a and b. Stream a is used to heat stream 4.
 | 302 Introduction to Process Engineering and Design

(mCp)tb = 10 - 6.5 = 3.5 kW/0C

Hot stream 2 contains ("'Cp) At = 8 x (160 - 90) = 560 kW heat. The same can be
used to increase the temperature of cold stream 3 from 60oC to 140oC, i.e. [7 x (140 -
60)] = 560 kW. For this heat exchange, heat exchanger B is used.
To heat the stream 3 from 140oC to 160oC, heat duty required is [7 x (160 - 140)] =
140 kW. Same can be furnished by hot stream lb. This is done in heat exchanger C.
Outlet temperature of hot stream 1 from heat exchange C is
Then (Cp\ (250-0=140
3.5 (250 - O = 140
t0 = 210oC
Remaining heat of hot stream lb is [3.5 x (210 - 130)] = 280 kW. If there exists an
opportunity to heat demineralised water for boiler feed make-up purpose, 280 kW heat
exchange can be effected in an econmiser (EC). If such an opportunity is not available,
stream lb can be cooled to I300C with the help of cooling water in a cooler.
Stream 4, available at 240oC from heat exchanger, can be heated to the desired tem-
perature of 260oC in a heater (H) with the help of circulating thermic fluid.
In all there will be 5 heat exchangers in the network; A, B, C, Hand EC, the last two
use hot and cold utilities, respectively.

Comments:
Here stream 1 is splitted in to two parts. Stream splitting has one advantage and two
disadvantages.
Advantage: Stream splitting removes the use of one extra heat exchanger in network.
Here if the stream 1 is not splitted, then total number of heat exchangers required in
network will be 6 instead of 5.
Disadvantages:
(i) In stream splitting, control of the flows in two branches is required.
(ii) Splitting a stream means each branch has a lower flow rate than that for the entire
stream. In case of no phase change heat transfer, lower flow rate means lower
heat transfer coefficient and larger exchanger area.
Suggested heat exchanger network design is based on the value of A '7^jn = 10oC. It is
Process Engineering Channel

not the optimum design. To arrive at the optimum network design detailed cost analysis
is required for the different values of A7^in. The value of A7^in which gives the mini-
mum total cost, is the optimum A^in, and design of heat exchanger network based on
that is optimum network design. A simple computer program can be developed for car-
rying out iterative calculations, varying A'i^lin values.

Example 6.1 I
@ProcessEng

Design the suitable heat exchanger network for atmospheric crude fractionation unit
based on the following data19- 20.
Solution:
1. Selection of pinch temperature difference; Fractions of crude petroleum oil pro-
vides relatively lower heat transfer coefficients. Hence, the optimum value of A^),
is relatively higher. Select the value of A^, = 20oC.
 Process Design of Heat Exchangers 303

Table 6.41 Table of Stream Data (Ref. 19, 20)

Stream No. Name of stream Temperature in, 0C Temperature out, 0C

1 Fuel oil 349 90

2 Gas oil 341 65
3 Kerosene 268 38
4 Reflux 251 77
5 Heavy Naptha 235 38
6 Light Naptha (Main) 168 71
7 Light Naptha (Pre flash) 136 71
8 Desalted feed 15.6 121
9 Pre-flash feed 120 194
10 Crude tower feed 189 368

Table 6.42 rhCp Data of Streams (Ref. 19. 20)

Stream No. Temperature range, 0C m C/r M W/0C

1 349 to 243 0.215

243 to 213 0.197
213 to 167 0.178
167 to 90 0.168
2 341 to 210 0.105
210 to 111 0.1
172 to 11! 0.087
III to 65 0.076
3 268 to 135 0.065
135 to 38 0.054
4 251 to 169 0.105
169 to 77 0.091
5 235 to 127 0.008
127 to 38 0.007
6 168 to 136 0.6
136 to 118 0.478
118 to 108 0.41
Process Engineering Channel

108 to 71 0.303
7 136 to 118 0.256
118 to 108 0.21
108 to 71 0.159
8 15.6 to 121 0.379
9 120 to 122 0.4
122 to 163 0.422
@ProcessEng

163 to 186 0.6

186 to 194 0.725
10 189 to 237 0.477
237 to 265 0.496
265 to 368 0.66
 Introduction to Process Engineering and Design

2. Table is prepared for drawing Grand Composite Curve.

Sample calculation for available heat in column 3 for the interval of temperature
change of hot streams from 2140C to 1680C: In this interval first five streams exist (all
hot streams from 1 to 5). Cold stream 10 also exists in this interval. But, it cannot be
considered in calculation of available heat (with hot streams).
Available heat within this interval
= 0.197 (214-213)4-0.178 (213- 168) (of Stream 1)4-(0.105 (214-210)4-0.1 (210
- 172) + 0.087 (172 - 168)) (of Stream 2) 4- (0.065 (214-168)) (of Stream 3) + [0.105
(214 - 169) 4- 0.091 (169 - 168)] (of Stream 4) + 0.008 (214 - 168) (of Stream 5)
= 20.949 MW.
In column 4, available heat indicates the cumulative or total heat available from the hot
streams at temperature /, when all hot streams (Stream No. 1 to 7) cool from the hottest
temperature 388° C to the temperature t0 C.
In column 5 required heat by cold streams for each temperature interval are calculated.
Sample calculations for the required heat in column 5 for the interval of temperature
from 1480C to 1940C of cold streams are as follows. In this interval two cold Streams
No. 9 and Stream No. 10 exist. Required heat by cold streams in this interval
= [(194 - 186) x 0.725 4- (186 - 163) x 0.6 4- (163 - 148) x 0.422] (of Stream 9)
4- [(194 - 189) x 0.477] (of stream 10)
= 28.315 MW
In column 6, cascaded required heat by cold streams at temperature t indicates the total
heat required by the cold streams to increase the temperature of cold streams from fC to
the maximum required temperatures :
Column 7 represents the net heat available for each interval.
Net heat available (column 7) = Heat available with hot streams (column 3)
- Heat required by cold streams (column 5)
Column 8 represents the cascaded or cumulative net heat available at any temperature
t. The most negative number in column 8 is -60.344 MW. It implies that minimum
amount of heat that must be supplied from the hot utilities. The same amount of heat,
60.344 MW is added in each number of 8th column. Resulting numbers are written in
the last column (column 9) as adjusted heat in MW. The point in the last column where
the adjusted cascaded heat is zero, represent the pinch point. Top most number in the last
column, 60.344 MW is the minimum amount of heat that must be supplied from the hot
utilities and the bottom most number of last column; 44.0974 MW is the minimum
amount of heat that must be removed by cold utilities.
Process Engineering Channel

3. Grand Composite Curve (GCC);

For this example, GCC is shown in Fig. 6.46. Pinch point occurs at 1680C of hot
streams temperature and 1480C of cold streams temperature.
4. Hot streams and cold streams exist above the pinch and below the pinch are shown in
Fig. 6.47.
For the maximum heat or energy recovery cold utilities cannot be used above the pinch
and hot utilities cannot be used below the pinch. Also, heat cannot be transferred across
@ProcessEng

the pinch.
Figure 6.47 also shows heat load (heat available or required) above and below the
pinch.
 Process Design of Heat Exchangers

Table 6.43 Cascaded Heat Flow Calculations

I 2 3 4 5 6 7 8 9
Hot Cold Avai- Cas- Requi- Cas- Net Cas- Adju-
stream stream lable caded red caded heat caded sted
tempe- tempe- heat heat heat heat heat cas-
rature rature caded
0 o
C c MW MW MW MW MW MW heat, MW
(388) 368 0 0 0 60.344
0 25.74 -25.74
349 (329) 0 25.74 -25.74 34.604
1.72 5.28 -3.56
341 (321) 1.72 31.02 -29.3 31.044
23.36 45.392 -22.032
268 (248) 25.08 76.412 -51.332 9.012
6.545 8.318 -1.773
251 (231) 31.625 84.73 -53.105 7.239
7.696 7.632 0.064
235 (215) 39.321 92.362 -53.041 7.303
10.08 10.017 0.063
214 194 49.401 102.379 -52.978 7.366
20.949 28.315 -7.366
168 (148) 70.35 130.694 -60.344 0
27.523 11.372 16.151
(141) 121 97.873 142.066 -44.193 16.151
1.019 0.779 0.24
(140) 120 98.892 142.845 -43.953 16.391
4.076 1.516 2.56
136 (116) 102.968 144.361 -41.393 18.951
48.165 17.434 30.731
90 (70) 151.133 161.795 -10.662 49.682
8.97 4.927 4.043
77 (57) 160.103 166.722 -6.619 53.725
3.594 2.274 1.32
71 (51) 163.697 168.996 -5.299 55.045
0.822 2.274 -1.452
Process Engineering Channel

65 (45) 164.519 171.27 -6.751 53.593

1.647 10.233 -8.586
38 (18) 166.166 181.503 -15.337 45.007
— 0.9096 -.9096
(35.6) 15.6 166.166 182.4126 -16.2466 44.0974
@ProcessEng

Sample calculation of heat load above the pinch for Stream No. 1:
Heat load above the pinch for Stream No. 1 = X(mCp)( Ar,
= 0.215 (349-243)+ 0.197 (243-213) + 0.178(213-168)
= 36.71 MW
Above the pinch design:
For the maximum energy recovery cold utility cannot be used above the pinch. But hot
utility can be used above the pinch. One of the possible network designs above the pinch
 Introduction to Process Engineering and Design

400/380
-< 60.144 k W
380/360

360/340

340/320

320/300

300/280

280/260

260/240 /
O
^ 240/220
I
f 220/200
D-
| 200/180 /
H
1 180/160 /
H /. -Pin ch Pc int
2 160/140

3 140/120
o
120/100

100/80

80/60

60/40 /

40/20 /
/
44 MW
ii . )974 1V1 VV w~ \1
20/0

01-20
Process Engineering Channel

0 10 20 30 40 50 60
Cascaded heat, MW

Fig. 6.46 Grand Composite Curve

is shown in Fig. 6.48. Here five hot streams and two cold steams exist above the pinch.
Heat available with Stream No. 5 above the pinch is 0.536 MW and is very low com-
@ProcessEng

pared to heat loads (heat available or required) of other streams existing above the pinch.
Hence the heat exchange above the pinch heat load of Stream No. 5 is not considered but
the same load is transferred or included in the design of network below the pinch. Here,
Stream No. 9 (cold stream) is splitted into four streams to exchange the heat with four
hot streams. Stream No. 10 (cold stream) is splitted into two steams to exchange the heat
 Process Design of Heat Exchangers

Heat Load above Heat Load below

Pinch
the Pinch the Pinch

0 = 36.71 MW I680C 0= 13.114 MW

90oC
0
349 C

0= 17.903 MW 1680C 0 = 8.455 MW

0
650C
341 C

0 = 6.50 MW 1680C 0 = 7.383 MW

380C
0
268 C

0 = 8.701 MW 1680C 0 = 8.281 MW

0 1TC
251 C

0 = 0.536 Mw 1680C 0 = 0.951 MW

0
380C
235 C
0 = 43.115 MW
1680C 710C

0= 12.591 MW
7 710C
1360C
15.60C
0 = 39.95 MW
12I0C
1940C 120oC
0 = 25.93 MW I48°C 0=11.772 MW

3680C 10
0= 104.8 MW
1890C

Fig. 6.47 Division of Hot Streams and Cold Stream Around Pinch Point

with two hot streams. Streams are splitted near the pinch while heater H is designed far
away from the pinch.
Process Engineering Channel

Below the pinch design:

For the maximum energy recovery hot utility can not be used below the pinch Refer
Fig. 6.49. If the stream splitting is required, then split it near the pinch. Design the heat
exchangers which utilize the utilities far away from the pinch. Here, below the pinch,
Stream No. 9 (cold stream) is again splitted at the pinch into four streams to exchange
the heat with the same four streams, from Stream No. 1 to 4. Another cold stream,
Stream No. 8, is also splitted into two streams to exchange the heat with Stream No. 1
@ProcessEng

and Stream No. 6. At the end. Stream No. 9 exchanges the heat with Stream No. 5. Total
six coolers are designed, far away from the pinch, at the end of network to meet the
process requirements.
Complete Design:
Complete design of heat exchanger network for the maximum energy recovery is ob-
tained by merging the two network designs, above and below the pinch. To reduce the
number of heat exchangers used for Stream No. 9 above the pinch. C, D, E and F are
 308 Introduction to Process Engineering and Design

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Process Engineering Channel

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@ProcessEng

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 Process Design of Heat Exchangers 309

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Process Engineering Channel

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@ProcessEng

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 310 Introduction to Process Engineering and Design

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Process Engineering Channel

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@ProcessEng
 Process Design of Heat Exchangers 31 I

combined with C2, D2, El and F2, respectively. C2, D2, E2 and F2 are the heat ex-
changers used below the pinch. For these combinations minor adjustments are done in
the temperatures of branch streams. Combined design or completed design is shown in
Fig. 6.50.
Note: Heat exchanger networking is normally carried on available heat sources/heat
sinks. However, in actual practice, overriding considerations such as fouling, start-up/
shut down conditions, etc. exclude some heat source/heat sink.

6.14 HEAT TRANSFER IN SOLIDS

Unlike heat transfer in liquids and gases, heat transfer in solids takes place chiefly
by conduction. Cooling of solids is often required after a dryer, a calciner, a
roaster or combustor. Metal powders, burnt lime, coal, etc. are cooled from high
temperature (in excess of 500oC). Urea, furnace grade carbon black, etc. require
cooling after drying. Pharmaceutical products (fine powder) require cooling after
drying before cooling. In food processing, coffee beans are cooled after roasting.
Beans, corn and peas are frozen by cooling with refrigerated air for preservation.
Cooling of hygroscopic solids is required for more than one reason. Granu-
lated or prilled fertilizer and carbon black with some moisture may agglomerate
on natural cooling due to moisture migration in silo. This results in lump forma-
tion. These lumps are quite hard and when broken by mechanical means produce
dusty material making it unsuitable for end use. However, caking tendency is not
observed in the same material if it is cooled (say below 60oC) in absence of
moisture.
Several technologies are available for cooling solids. Although compact plate
type heat exchangers are developed for cooling of solids, their application is
limited due to cost and adherence of sticky solids to the heat exchanger surface.
Direct contact coolers with or without indirect cooling (with cooling water)
are popular for cooling of solids. Adham has described various solids cooling
technologies at length. Heat recovery from hot gases, coming out of the cooler is
possible depending on temperature of gases and its possible use elsewhere in the
plant. Chiefly, four types of coolers are in use for most applications of solids
cooling.
(a) Stationary cooler
Process Engineering Channel

(b) Rotary cooler

(c) Fluid bed cooler
(d) Conveyor cooler

6.14.1 Stationary Coolers

Simple version of a stationary cooler (Fig. 6.51) has a bin with internal cooling
@ProcessEng

surface. It is recommended for free flowing material and is unsuitable for wet,
very fine and sticky powders. Overall heat transfer rate in the cooler is quite low
and hence larger cooling surface is required.
Solids travel in a plug flow manner and a temperature gradient from top to
bottom is observed. Stationary coolers are recommended for moderate inlet tem-
perature (say 300 to 400oC) and for heat duties not exceeding 150 kW. Free
 Introduction to Process Engineering and Design

Hot Solids In
2/>

Circulating
Condensate Out

Circulating
Condensate In a/U/li/M/H/H/H/

Cooled Solids Out

Fig. 6.51 Stationary Cooler with Water Cooled Plates

flowing powder up to 100 (im size can be cooled in such a cooler. Barring these
limitations, stationary coolers are compact, require minimum or no auxiliary equip-
ment, require no off-gas treatment and are simple to operate. Cooling up to 60 to
70oC should be possible with this cooler with circulating water maintained at a
temperature of 30 to 350C.

6.14.2 Rotary Coolers

This versatile cooler can handle different type of solids and can be used as direct
or an indirect cooler with or without heat recovery. Although it can be used for a
wide range of solids, it is a preferred equipment for coarse particles. In this types
of coolers, hot air (or gas) flows in counter current direction of solids, increasing
the thermal efficiency. Cooling coils can be embedded in the bed to provide indi-
rect cooling. Heat from the hot air, coming out from the cooler, can be recovered
in a number of ways.
Process Engineering Channel

Figure 6.52 is a simple sketch of a rotary cooler. Diamenter of the cooler is

restricted below 3 m for the considerations of fabrication and transportation. Drive
mechanism for the cooler also imposes restrictions on the dimensions. Length to
diameter ratio is kept in the range of 4 to 10. To avoid passing of solids without
coming in contact with air, depth of material is kept in the range of 30-40% of
radius. Such equipment can be used for drying as well as cooling. In carbon
@ProcessEng

black industry, ceramic industry, metal powder industry, etc., this equipment is
popular.

6.14.3 Fluid Bed Cooler

Coarse small particles (below 2-2.5 mm) can be fluidized with air or gas. How-
ever, very fine powders (less than 10 (im) resists smooth fluidization. So fluid-
 Process Design of Heat Exchangers 313

Hot Solids In

Spray Water In
(Optional) Hot Gases Out

Cold Air In

Cooled Solids Out

Fig. 6.52 Rotary Cooler with Direct Air and Spray Water Cooling

ized bed cooler can be considered for the intermediate size solids. In Fig. 6.53,
4-stage fluid bed cooler with embedded cooling coils is shown.

Hot Solids In Hot Gases

Dust Laden Hot Gases ITo Atmoshphere

Circulating
Condensate Out
Freeboard
Dust
Circulating
Condensate In
(Optional) A/WN lAAA/N l/V\AAl lAAAAl
A
Fluidizing Air Distribution Plate

Cooled Solids Out

Cold Air In
(a) Fluid Bed Cooler
Process Engineering Channel

T T I "T"
Air Air Air Air
Perforated Convex Nozzles Grate Bars
Plate Perforated Plate
(b) Typical Distributors for Fluidized Beds
@ProcessEng

Fig. 6.53 Four Stage Fluidized Bed Cooler with Indirect Water Cooling

Spray cooling is an option both in rotary as well as fluid bed coolers but it has
to be executed with caution. Hot air wet bulb temperature should not be allowed
to exceed 80oC and fluid or moving bed temperature is not allowed to fall below
150oC to prevent moisture absorption by the solids.
 Introduction to Process Engineering and Design

Fluid bed cooler can handle free flowing and non-sticky solids. Heat transfer
rate is excellent in a fluid bed cooler among all solid-cooling equipments. How-
ever, it needs an auxiliary equipment such as a cyclone or a bag filter for off-gas
treatments to trap fines. This equipment is relatively simple in operation and easy
to maintain.
Removal of fines from the solids may be considered as an advantage. The
product after cooling is free from dust and its particle size distribution is in the
narrow range making it a preferred marketable product.

6.14.4 Conveyor Coolers

Variety of conveyor coolers are available. Vertical spiral cooler, moving grate
cooler, vibrating pan cooler, screw conveyor coolers, etc. are a few of them. The
screw conveyor cooler is normally used for indirect cooling of solids with cool-
ing water which flows in the conveyor shell jacket and the hollow shaft. Screw
conveyor coolers can be used for free flowing solids, normally coarse in nature
(0.1-12 mm). Screw conveyor coolers can be advantageously used for cooling as
well as conveying. Single or multiple screw designs are available but double
screw design is popular up to a maximum length of 8.5 m.
Process design of cooling equipments of solids can be well explained by the
following example.

Example 6.12
Urea prills from a prill tower in a fertilizer plant have a temperature of I()0oC and mois-
ture content of 1.5 to 2% (by mass). They need to be cooled to 60oC before sending to
silo for storage to prevent caking and lump formation. Average sieve analysis of prills is
given in Table 6.44.

Table 6.44 Distribution of Urea Prills by Size

Size of prills, mm Mass%

+2.4 0.8
+2.0 9.0
+ 1.7 56.3
+ 1.4 26.6
Process Engineering Channel

+ 1.0 7.3

Physical properties of urea:

Particle density. ps = 1.335 kg/L
Bulk density, psl) = 0.758 kg/L (without compaction)
Thermal conducity, ks = 80 W/(m ■ 0C)
Heat capacity, Cs = 1.775 kJ/(kg • 0C)
@ProcessEng

Cooling Mediums
(a) Circulating condensate is proposed to be used in the stationary cooler to avoid
possibility of fouling in the plates. Supply and return temperatures may be taken as
35 and 450C, respectively. Hot condensate is passed through a shell and tube heat
exchanger in which it is cooled to 350C with the help of cooling water of 30oC
which is recirculated.
 Process Design of Heat Exchangers

(b) Ambient air at 440C is to be used in rotary and fluid bed coolers. Outlet air tem-
perature from the coolers may be fixed to be 750C.
Work out process design of stationary, rotary and fluid bed coolers to process 601/
h urea prills. While there is hardly any change in moisture content in the stationary
cooler, moisture content of prills gets reduced to 0.5 mass % in rotary and fluid bed
cooler.
Overall heat balance:

75 + 44
Average temperature of air = —-—

= 59.50C
= 332.65 K

22.4136x332.65
Molar volume of air = -
273.15
= 27.296 m3/kmol

Density of air, p„ = = 1.061 kg/m3

27.296
Moisture removal of urea = 60000 (0.015 - 0.005) = 600 kg/h
Total heat load of prill cooling in rotary and fluid bed coolers,
= 60 000 x 1.775 (100 - 60) + 600 x 2644
= 4260 000+ 1586 400
= 5846 400 kJ/h
= 1624.0 kW
Average heat capacity of air at 59.50C,
Cpa = 1.005 kJ/(kg ■ 0C)
Air is heated from 440C to 750C.

5846 400
Mass flow rate of air, qn,n =
1.005(75-44)

= 187 655 kg/h

Volumetric flow rate of air, qva = 187 655/1.061
= 176 866 m3/h
Viscosity of air at 59.50C, = 0.072 kg/(cm • h)
Process Engineering Channel

In case of stationary cooler, heat lead,

02 = 4260 000 kJ/h (no evaporation load)
= 1183.33 kW
Flow rate of circulating condensate,

4260 000
qmi. = = 101 748 kg/h
mc
4.1868(45-35)
@ProcessEng

= 101.7 m3/h
Process design of stationary (bulk flow) Cooler;
Refer Fig. 6.48.
Assume 2h = 5 cm
b = 2.5 cm = 0.025 m
 Introduction to Process Engineering and Design

In a stationary cooler, solids travel in plug flow and. therefore, a temperature gradi-
ent in bulk solids is observed. Following equation relating to the unsteady-state
heat transfer from a solid, can be used to calculate cooling time of the solids.

- (/I + 0.5 ) —
h-t2 _ y 2
(6.111)
h - ti »=o(r7 + 0.5)2 ;r

where, r, = Inlet solid temperature, 0C

tj = Outlet solid temperature 0C
= Inlet circulating condensate temperature, 0C
^2 = Outlet circulating condensate temperature, "C
a = Thermal diffusivity in solid, m2/h
= V(P, • Q)
ks = Thermal conductivity of solid, kJ/(h-nv0C)
Cs = 1.775 kJ/(kg-0C) for urea
6 = cooling time, h
Above equation assumes that convective transfer coefficient of cooling water
and thermal conductivity of the plate material (SS in this case) is much larger than
ks. This assumption may be considered valid for urea prills.
ks = 80 W/(m • 0C)
= 288 kJ/(h-m-0C)

288
a=
1335 x 1.775

= 0.121 54 nr/h

60-45
LHS of Eq. (6.111) =
100-45
= 0.272 73
Spreadsheet can be useful in solving Eq. (6. 111). Substituting values of b and a in
RHS of the equation and solving by trial and error,
6 = 0.0023 h = 8.28 s
Hold-up required for solids cooling,
Process Engineering Channel

60 000 x 8.28
= 182.06 m 3
3600x0.758
Single silo or bin of such large operating volume with cooling plates would not
be desirable for operational and maintenenace reasons. Cooling height of at least 2
m is recommended.
Overall heat transfer coefficient of 175 w/(m2-0C) will be safe to design the cool-
@ProcessEng

ing surface.
ATf = 100 - 45 = 550C
= 60-45 = I50C

55-15
Aqm = —:—- = 30.79oC
ln(
(9)
 Process Design of Heat Exchangers

4260000
Heating surface requirement. A =
30.79x175x3.6

= 219.61 m2 (min.)
Four or more silos may be provided. Distance between plates for cooling water
flow should be kept at least 2 cm. Silos and plate coolers with HTA, exceeding 220
m2, can be easily sized for the required heat duty.
For four silos,
Hold-up volume of solids = 182.06/4 = 45.515 m3
Assume cooling (plate) height = 3 m
Cross-sectional area of silo = 45.515/3 = 15.172 m2
Consider square construction of the silo.

Each side = V 15.172 = 3.895 say 3.9 m

Plate length = 3.5 m
Width between two plates = 5 cm

350
No. of pairs of plates = ^ ^

= 35
HTA per pair of plates = 3.5 x 3 x 2
= 14 m2
HTA per silo = 14 x 350 = 490 m2
Total HTA = 490 x 4 = 1960 m2

Available HTA lOfso

= = 8.92 (much in excess)
Required HTA 219.61

In order to avoid clinging of urea dust, present in the feed of silo, a small quantity
of dry air is injected from bottom. The exhaust air from the cooler is directed to prill
tower bottom.

II. Process Design of Rotary Cooler

Assume diameter of rotary cooler as 2.75 m. Air is passed in countercurrent (horizontal)

fashion to solids flow.
Process Engineering Channel

Cross sectional area of cooler, A2 = (7r/4) (2.75)2

= 5.939 57 m2

176866
Velocity of air = = 8.272 m/s
3600 x 5.939 57
This is a very high velocity and will blow dust and fine area prills. Normally in a
rotary cooler, velocity of 1.5 m/s is preferred. This will call for six rotary coolers to be
@ProcessEng

used in parallel.

60000
Flow of urea prills/cooler = —^—

= 10 000 kg/h = 10 t/h

 Introduction to Process Engineering and Design

Flow of air through each coolers,

176866
<?var =
6
= 29 477.7 m3/h at inlet

29 477.7
Velocity of air at inlet =
3600 x 5.939 57

= 1.379 m/s (< 1.5 m/s)

Rotary cooler length can be calculated by the following equation.
L = NtH, (6.112)
where, L = Rotary cooler length, m
Nt = Number of transfer units
Hr = Height (length) of transfer unit, m

Ate
N.= — (6.113,
1X1
hn
where, = rg ((ut - ^ in, 0C

— —
( fs, in tg, out ) - ( ^s, oul tg, in )
A'4,
('s, in 'g, out )
In
—
( out tg, in )

(100 - 75)-(60 - 44)

= 20.17oC
N
100-75
In
60-44

75-44
N, = = 1.537
20.17
Preferred range of N, is 1.5 to 2.5.

u _ 1000 GQ

Uv
Process Engineering Channel

where, G = Mass flow rate per unit are of air, kg/(m2 • s)

Ca = Heat capacity of air = 1.005 kJ/(kg • s)
Uv = Overall volumetric heat transfer coefficient, kJ/(m3 • s ■ 0C)
= 237 G0-67/D
D = Rotary cooler diameter, m

187 655 i
@ProcessEng

G= x
6 3600x5.939 57

= 1.462 69 kg(nr • s)
Uv = 237 (1.462 69),)'67/2.75
= 111.2 kJ/(m3 - s - 0C)
 Process Design of Heat Exchangers

1000x1.462 69x1.005
H, =
111.2
= 13.2
L = 1.537 x 13.2 = 20.29 m or 20.3 m
LID = 20.3/2.75 = 7.38
Rotary coolers, commonly in use, have L/D ratio in the range of 4 to 10. Bed depth of
about a meter is recommended in the cooler. Above design is for cooling with air only. If
cooling surface is provided across the length for indirect cooling with cooling water,
heat transfer rate can be estimated by considering overall heat transfer coefficient of 55-
110 W/(m2-0C).

III. Process Design of Fluid Bed Cooler

For determining the fluidizing velocity, mean particle diameter (dp) is required. Mean
particle diameter,

4.= S- (6.114)

d,

where. dp = Mean particle diameter and

m | = Mass fraction of particle diameter, di

m. 0.008 + 009 + 0.563 + 0.266 + 0.073

I
d: 2.4 1.7 1.4

= 0.6425
dp = 1/0.6425 = 1.556 mm
For estimating fluidization velocity, use of following eauation22 is recommended.

1/2
5x10 dppg (ps -pL,)g
Rem = 33 J2 + - 33.7 (6.115)

where. Rem = Reynolds number at minimum fluidization velocity

dp = 1.556 mm = 0.001 556 m
pg = 1.061 kg/m3
Process Engineering Channel

ps = 1.335 kg/L = 1335 kg/m3

g = gravitational acceleration
= 9.81 m/s2
livo = 0.072 kg/(m • h)
1/2
5x 10 (0.001556)3 1.061(1335-1.061)9.81
Re.„ = 1135.65 + - -33.7
@ProcessEng

(0.072 f

= (1135.65 + 5044.89)l/2-33.7
= 44.92
 Introduction to Process Engineering and Design

Minimum fluidization velocity is related with Reynolds number as

RemV8
Ul =
" 3600 Pj, dp

44.92 x 0.072
~ 3600x1.061x0.001556

= 0.54 m/s at ambient temperature

At the minimum velocity, fluidization starts. Terminal velocity is the velocity above
which the solids particles will be pneumatically conveyed. Reynolds number (/?<?,) at the
terminal velocity is derived by

7
CjRej = 1.6 x 10 g dp — — (6.116)
2
H
where, Q = Drug coefficient which depends on sphericity (^s) of the particles
& = 0.6 for broken solids and the same can be taken for urea prills
Q = 6 for (/)s = 0.6

L6xl07 x (0.00 1 556)3 x 1.061(1355-1.061)

Re;
(0.072 )2 x 6

= 26 906
Re, = 164

Ret^g _ 164x0.072
u, _
3600 p d 3600x1.061x0.001556" 1-987 m/s

Actual fluidization velocity will be between um and ut. Select u = 1 m/s for normal
fluidization.
Volumetric flow rate of air, qva = 176 866 nrVh

176866
Area of fluidization, A-,=
- 1x3600

= 49.129 m2
Process Engineering Channel

Selected width, w = 3 m
Length, L = 49.129/3 = 16.376 m
To improve thermal efficiency, total length will be divided into a number of stages.
Select 4 stages for fluidization.

16 376
Length of each stage = —-— = 4.094 m, say 4.1 m
4
@ProcessEng

Staging will be beneficial for crossflow of solids. Bed depth of 0.4 to 0.5 m is ad-
equate in each stage. Assuming bed depth of 0.5 m, hold-up of urea in fluid bed cooler
= 49.129x0.5 x758
= 18 620 kg
This means residence time (6) of urea prills in the fluids bed cooler will be 18.62 min;
or approximately 20 min.
 Process Design of Heat Exchangers

Peak pressure drop in the bed22.

Ap, 6.8 A_
+ 0.8 -34.4- (6.117)
H tan 7 VDC H
PbS

where. A pp = Peak pressure drop, kN/m2 or kPa

H = Height of bed. m = 0.5 m
pb = Bulk density, kg/m3 = 0.758 kg/L
g= 9.81 m/s2
V = Angle of internal friction. For gramular solids, consider it to be
55°.
D, = Fluid inlet orifice diameter
= 2 cm = 0.02 m (assumed)
Dc = diameter of equivalent cross-section

'—(49.129) = 7.909 m
K

a/a 6.8 0.001556

a02
-1 + 0.8 - 34.4 x
0.5x0.758x9.81 tan 55 V 7.909 ) 0.5

= 0.812-0.107 = 0.705
kPp = 2.62 kPa = 267 mm WC
In normal course, pressure drop will vary between 30 to 50% of peak pressure drop
(i.e. 80-135 mm WC) across the bed. To this add friction loss in the ducts which will
give the fan pressure requirement.
During fluidization, broken and prills with poor mechanical strength will break and
form dust due to attrition. This is expected to give higher dust load than the other two
types of coolers. Dust will be separated from exhaust air and will be allowed to fall in a
dust dissolving tank for reprocessing. Urea prills, coming out from the fluid bed coolers
will be of near uniform size and with definite mechanical strength which will not break
during storage in silo.

Exercises
Process Engineering Channel

6.1 Select the correct answer.

(a) For an exchanger with no phase change service design conditions are: Hot
fluid is cooled in counter current manner from 2130C to 570C with a cold fluid
which is heated from 29.50C to 40.5oC. Other parameters being maintained
the same, if hot fluid inlet temperature is reduced to 201oC and cold fluid inlet
temperature is increased to 350C, then:
@ProcessEng

(i) Hot fluid and cold fluid outlet temperatures will change to 60oC and
45 0C, respectively.
(ii) Hot fluid outlet temperature will change to 60oC while cold fluid outlet
temperature will remain as 40.5oC.
(iii) Hot fluid outlet temperature will remain 570C while cold fluid outlet
temperature will change to 450C or
(iv) Data not sufficient to predict.
 Introduction to Process Engineering and Design

(b) In the heat transfer equation for heat exchanger, the heat transfer rate appears
to be directly proportional to the heat transfer area. Hence (other parameters
remaining the same) for double the heat transfer area, the heat transfer rate will
be
(i) doubled
(ii) more than doubled or
(iii) less than doubled.
(c) A shell and tube, horizontally installed heat exchanger with 2-tube passes has
pressure gauges (P, and fS) installed, respectively on the inlet pipe to the lower
nozzle and on the outer pipe from the upper nozzle of the channel. The pres-
sure gauges are approximately 1.4 m apart. The difference in the readings (P,
- Pj) is 0.42 bar. Each nozzle accounts for 0.07 bar pressure drop. Estimate the
difference in pressure reading (as P, - Pj) for the following cases.
(i) Tube side passes are changed from 2 to 4 and
(ii) Tube side flow rate is doubled.
[Answer: (a) 1.42 bar, (b) 0.85 bar or (c) 0.42 bar]
6.2 A fire tube waste-heat boiler generate steam at a pressure of 10.34 bar g. It is de-
signed for a gas flow of 80 000 kg/h from an incinerator. Gas is designed to be
cooled from 60()oC to 260oC. On a particular day, the gas flow is 55 000 kg/h and
inlet temperature to the boiler is 500oC and steam is generated at 10.34 bar g. What
will be the expected gas outlet temperature if the overall heat transfer coefficient is
proportional to mass flow rate of gas to the power of 0.8? Assume other properties
of flue gases to be nearly the same.
Assume overall thermal efficiency of the boiler to be 95% in both the cases.
Average heat capacity of fine gases may be taken as 1 kJ/(kg • K). Demineralized
water enters steam drum at 350C. Calculate steam generation from the boiler in
both the cases.
Data: Saturation temperature of steam at 10.34 bar g = 185.50C
Enthalpy of saturated steam at 10.34 bar g = 2780.8 kJ/kg
Enthalpy of water at 350C = 146.6 kJ/kg
6.3 120 000 kg/h of ethanol is to be cooled from 780C to 40oC by cooling water as
coolant. Cooling water enters at 320C and leaves at 40oC. Design shell and tube
heat exchangers for the different tube lengths 1.5 m, 3 m, 4.5 m and 6 m.
6.4 3000 kg/h of nearly pure saturated Phosphorous Oxychloride (POCI3) vapour at 15
kPa g is to be condensed and cooled to 60oC by cooling water which is available in
plant at 320C. Design the suitable shell and tube heat exchanger for the given duty
Process Engineering Channel

using following data.

Data:
Tube material: Graphite
Tube OD : 25 mm
Tube ID : 20 mm
Thermal conductivity of graphite: 150 W/(m • K)
Molar mass of POCI3: 153.4 kg/kmol
Specific heat of liquid POCI3: 0.92 kJ/(kg • 0C)
@ProcessEng

Latent heat of vaporization of POCI3: 229 kJ/kg

Thermal conductivity of liquid POCI3: 0.173 W/(m • 0C)
Viscosity of liquid POCI3 = 1.1 cP
Liquid density of POCl3= 1675 kg/m3
Condensation temperature of POCI3 at 15 kPa g = 110oC
Viscosity of POCI3 vapour. /dv = 1000 x 10^7 Poise
 Process Design of Heat Exchangers

6.5 Design vertical thermosyphon reboiler for acetic acid dehydration column based on
following data :
(a) Feed is liquid at 30oC.
Feed flow rate = 12 000 kg/h
Feed composition = 80% acetic acid and 20% water (by mass)
(b) Distillate is saturated liquid at 100.6oC
Flow rate of distillate = 3000 kg/h
Distillate composition = 20% acetic acid and 80% water (by mass)
(c) Residue is nearly pure saturated acetic acid at 1380C and at 179.5 kPa a.
(d) Reflux ratio, R = 4.2.
(e) Latent heat of vaporization
XAA = 25 732 kJ/kmol at 293.8 K
Xw = 40 677 kJ/kmol at 373.15 K
(f) Crtical temperature of acetic acid = 592.71 K
Crtical temperature of water = 647.11 K
(g) Fleat capacity equation for liquids
cml =a + br+cr2 + dr3
where, Cm| = Liquid heat capacity, kJ/(kmol ■ K)
T = Absolute temperature, K

Table 6.45 Heat Capacity Data4

a h x 103 cx 106 dx 109

Acetic acid -36.0814 604.681 -393.957 -561.602

Water 18.2964 472.118 -1338.78 1314.24

6.6 50 000 kg/h cold air is required at 180C temperature. Chilled water with 60C supply
temperature and 80C return temperature is to be used as cooling medium. Design a
suitable finned tube heat exchanger with box type shell.
Hint: Atmospheric air contains water vapour. Hence condensation load of water
vapour must be considered in the calculation of heat duty. Air saturated with wa-
ter vapour at 40oC can be considered as design condition.
6.7 Synthesize the heat exchanger network for the following five process streams such
that resulting heat exchanger network will require the minimum hot and cold utili-
Process Engineering Channel

ties. Also find the values of minimum utilities (hot and cold) required.

Table 6.46 Process Stream Data23

Stream Type w Cp, kWAC tin, 0C tout, 0C

1 Hot 228.5 159 77

2 Hot 20.4 267 88
@ProcessEng

3 Hot 53.8 343 90

4 Cold 93.3 26 127
5 Cold 196.1 118 265

6.8 Design a kettle type reboiler which must provide 2000 kg/h of ethylene glycol va-
pour to a distillation column at 30 kPa a pressure at bottom.
 Introduction to Process Engineering and Design

References

1. TEMA, 8,h Ed., Standard of the Tubular Exchanger Manufacturers Association, New
York, USA, 1988.
2. Perry, R. H. and Green D., Perry's Chemical Engineers' Handbook, 6,h Ed., McGraw-
Hill, USA, 1984.
3. Pfaudler Heat Exchanger Databook, Pfaudler International GmbH, Basel, Swit-
zerland.
4. Sinnott, R. K., Coulson and Richardson's Chemical Engineering, Vol. 6, Revised
2nd Ed., Asian Publishers Books Pvt. Ltd., New Delhi, 1998.
5. Kern, D. Q., Process Heat Transfer, McGraw-Hill, USA, 1950.
6. Ludwig, E. E, Applied Process 3"1 Design for Chemical and Petrochemical Plants,
Vol. 3, 3rd Ed. Gulf Publishing, USA, 2001.
7. Smith. R.A., Vaporisers: Selection, Design and Operation, Longmans, UK, 1986.
8. Dadyburjor, D. B., Chem. Engg. Progr, 74(4), 1978, p. 86.
9. Bhatt, B.I. and S. M. Vora, Stoichiometry, 4th Ed.. Tata McGraw-Hill Publishing
Co. Ltd., New Delhi, 2004.
10. Hughmark, G. A., Chem. Eng. Progr. 60(7), 1964, p. 59.
11. Fair, J. R., Chem. Engg., 70(14), July, 1963, p. 119.
12. Frank, O. and Prickett, R. D., Chem. Engg., 80(20), September 3, 1973, p. 107.
13. Saunders, E. A. D., Heat Exchangers, lsl Ed., Longmans, UK, 1988.
14. Buonopane, R. A., Troupe, R. A. and J. C. Morgan, Chem. Engg. Progr., 59(7),
1963, p. 57 to 61.
15. Bhatia, M. V. and P. N. Cheremisinoff, Process Equipment Series, Heat Transfer
Equipment, Vol. 2, Technomic Publishing Company, Inc., USA, 1980.
16. Minton, P. E., Chem. Engg., 77(10) May 4, 1970, p. 103.
17. Wadekar, V. V, Chem. Eng. Progr. 96(12), 2000, p. 39 to 49.
18. Linhoff, B., Townsend, D. W. and G. W. Hewitt, User Guide on Process Integra-
tion for the Efficient Use of Energy, Rev. Ed., Institution of Chemical Engineers,
London, UK, 1994.
19. Bagajewicz, M. and J. Shuncheng, Ind. Eng. Chem. Res., 40(2), 2001, 617-626.
20. Bagajewicz, M. and J. Soto, Ind. Eng. Chem. Res., 40(2), 2001, p. 627-634.
21. Adham, K., Chem. Engg. Progr.. 96 (8), 2000, p. 37.
22. McKetta J.J. and W.A. Cunningham, (Ed.) Encyclopedia of Chemical Processing
and Design, Vol. 23, Marcel Dekker, Inc., USA. 1985, p. 51 and 76 to 79.
Process Engineering Channel

23. Linnhoff. B. and T. N. Tjoe, Chem. Engg., 93(8), April 28. 1986. p. 47 to 60.
24. Chopey, N. P., Handbook of Chemical Engineering Calculations, 2nd Ed., McGraw-
Hill, Inc., USA, 1994, Ch-7.
25. McAdams, W. H., Heat Transmission, 2nd Ed., McGraw-Hill, Inc., USA 1942.
@ProcessEng
 Chapter j

Design of Liquid-

Liquid Extractor

7.1 INTRODUCTION

Liquid-liquid extraction is the separation of the components of a liquid solution

by contacting it with another insoluble liquid solvent. One of the components or
certain group of the components of the solution (feed) is selectively soluble in
the solvent. It is called solute. After the contact, components of liquid feed are
distributed between two immiscible liquids; called extract phase and raffinate
phase. Solvent rich phase is called extract phase and solvent lean phase is called
raffinate phase, respectively. A component which is left behind in the raffinate
phase after extraction is called diluent.
Solvent extraction finds many applications in industry. Take an example of
separation of solution containing 10% by mass acetic acid and 90% by mass
water. Separation of these two is very difficult by distillation as this mixture pro-
vides very low relative volatility. In liquid-liquid extraction, acetic acid-water
solution is contacted with a solvent such as ethyl acetate. The solvent makes the
Process Engineering Channel

immiscible or partially miscible liquid mixture with water. Acetic acid is selec-
tively extracted in ethyl acetate. At the end of single stage extraction two
immiscible liquid layers are obtained. Ethyl acetate rich layer is called extract
phase and water rich layer is called raffinate phase.
Liquid-liquid extraction is an important unit operation and finds applications
in refinery, pharmaceutical industries, metallurical industries and other indus-
@ProcessEng

tries. In refinery, after distillation, liquid-liquid extraction is the most widely used
unit operation.
Invariably extraction will have to be followed by another unit operation, such
as distillation for separation of solute from the extract phase.
 Introduction to Process Engineering and Design

7.2 IMPORTANT INDUSTRIAL APPLICATIONS OF

LIQUID-LIQUID EXTRACTION1 2

(i) Separation of 10% to 30% acetic acid in aqueous solution by using ethyl
acetate or ethyl ether as solvent.
(ii) Recovery of uranium from ore rich liquor. Solvent for this case is alkyl
phosphate in kerosene.
(iii) Separation of long-chain fatty acids from vegetable oil by using propane as
solvent.
(iv) Propane deasphalting. Separation of lube oil from residuum (residue of
vacuum distillation column of refinery) by using propane as solvent.
(v) Separation of tantalum and niobium. It involves dissolution of this mixutre
in hydrofluoric acid, followed by extraction with Methyl Isobutyl Ketone
(MIBK). Similarly liquid-liquid extraction is used for the metal separations
such as uranium-vanadium, hafnium-zicronium and tungsten-molybdenum
mixtures.
(vi) Phosphoric acid and boric acid are finally purified by liquid-liquid extrac-
tion.
(vii) Liquid-liquid extraction is used for the separation of the mixture of aro-
matic and paraffinic hydrocarbons of nearly the same molar mass (e.g. a
mixture of benzene and haxane). For this case, solvents used are liquid
sulphur dioxide, diethylene glycol or sulfolane. Extractive distillation is
also used for the same application.
(viii) Many pharmaceutical products are produced in the form of complex mix-
ture. From this mixture, pure product is separated by liquid-liquid extrac-
tion; e.g. penicillin, resorcinol, etc.
(ix) In the petroleum refinery the separation of pure benzene and toluene from
aromatic rich feed stock is carried out by extraction. In this case sulfolane
is used as solvent.
(x) For dearomatization of raw hexane fraction (or for the production of food
grade hexane) using N-methyl pyrrolidone (NMP) as solvent.
(xi) For dearomatization of the straight run kerosene fraction (or for the pro-
duction of superior kerosene) using sulpholane as solvent.
(xii) For the purification of lube oil using furfural or NMP as solvent.
Process Engineering Channel

(xiii) In an aqueous effluent containing very high COD, organic solvent (such as
toluene or xylene) is effectively used to extract out COD causing components.
(xiv) In the manufacturing process of MTBE, methanol is separated from the
mixture of methanol and C4 stream by using water as solvent.
(xv) For extraction of unsaturated fatty acids from a mixture of fatty acids using
fulfural as solvent.
@ProcessEng

7.3 PHASE EQUILIBRIUM

Distribution coefficient or partition coefficient K or m is defined as

.y mass fraction of solute in extract phase

K or m= — = (7.1)
X mass fraction of solute is raffinate phase
 Design of Liquid-Liquid Extractor

In liquid-liquid extraction, all the components are present in both extract and
raffinate phases at equilibirum. At equilibirum, acitivity of any component is
same in both phases.

K= YrX = YQy (7.2)

where, A,. = activity of component in raffinate phase
ke = activity of component in extract phase
yr, ye = activity coefficients of components in raffinate/extract phase
y = mole fraction of component in extract phase
x = mole fraction of component in raffinate phase

J Yr
K'= - = — (7.3)
Ye
where K' = distribution coefficient in mole fraction units
Large collections of experimental equilibrium data are now available for
liquid-liquid systems. One source is "Liquid-Liquid equilibrium Data Collection "
by Sorenson and Arit, DECHEMA, Frankfurt, Germany. In Perry's Chemical
Engineers' Handbook, (Ref. 3) distribution coefficients for a few ternary systems
are given (Table 15.5 of 6lh Ed.)

7.4 DESIRABLE SOLVENT PROPERTIES OR CHOICE

OF SOLVENT

7.4.1 Selectivity

The relative separation or selectivity is defined as the ratio of ratios of solute to

nonsolute components in extract phase to the same in raffinate phase at equilib-
rium. It is represented as a or p.
For all useful extractions, a> 1. If «= 1, it means no separation or no extrac-
tion. It represents the separation power of solvent. Higher the selectivity, lesser is
the number of theoretical stages required for the desired separation. Dilute solute
concentration generally gives the highest selectivity.

7.4.2 Distribution Coefficient

Process Engineering Channel

Distribution coefficient K or m is the ratio of mass fraction of solute in extract

phase to mass fraction of solute in raffinate phase at equilibrium. K = y/Xat
equilibrium as defined in Eq. (7.1).
It is not necessary that K should be greater than 1. K can be less than 1. But
higher value of K is desirable because higher the distribution coefficient, lesser is
the amount of solvent required for desired separation. Unfortunately solvents
which provide the higher value of K normally provide poor value of a.
@ProcessEng

7.4.3 Recoverability

It is always necessary to recover the solvent from extract phase for reuse. Hence,
selected solvent must be easily recoverable from the extract phase. In most of the
cases, solvent is separated from extract phase by distillation. If selected solvent is
 Introduction to Process Engineering and Design

to be separated or recovered by distillation than it should not form an azeotrope

with the solute and also it should provide higher value of relative volatility. Lesser
value of latent heat of vaporization of solvent is also desirable for low cost of
recovery. Water is not an attractive solvent for extraction as it forms azeotrope or
non-ideal solution with many organics and it has very high value of latent heat of
vaporization.

7.4.4 Capacity

Capacity of a solvent to extract the solute is measured in terms of maximum

solubility of the solute in solvent or in terms of solubility limit. Higher the solubility
limit, lesser is the amount of solvent required. Solute should be significantly
soluble in the selected solvent.

7.4.5 Insolubility of Solvent

Low solubility of solvent in the raffinate phase is desirable. Solvent which is

more insoluble is preferred. More insoluble solvent can separate wide range of
composition of feed mixture. Also, it gives less solvent loss and adds less impurity
in the final raffinate. Generally, a solvent which is more insoluble provides higher
selectivity.

7.4.6 Density

Higher density difference between solvent and diluent or extract and raffinate
phase is desirable. It makes the decantation easier. In most of the systems, density
difference decreases to zero at plait point, but in some system it can become zero
at an intermediate solute concentration and can invert the phases at higher con-
centration. For such a system, in the desired range of separation in the extractor,
if density difference passes through zero then use of continuous contact equipment
like packed tower is not preferred but mixer-settler type stage wise extractor can
be used. Other option is to use two continuous contact extractors in series.

7.4.7 Interfacial Tension

A high interfacial tension promotes rapid coalescence and generally requires high
Process Engineering Channel

mechnical energy for agitation to produce small droplets. Conversely, low inter-
facial tension requires lesser mechanical energy for agitation to produce small
droplets but at the same time it provides slow coalescence rates. Usually interfa-
cial tension decreases with increase in solute concentration and increase in mu-
tual solubility and falls to zero at plait point. Very high and very low interfacial
tension of selected solvent is not desirable, otherwise higher collision rate is more
important, hence moderately high interfacial tension is preferred.
@ProcessEng

7.4.8 Chemical Reactivity

The solvent should be inert towards the other components of extraction system
and to the common materials of construction.
 Design of Liquid-Liquid Extractor

7.4.9 Viscosity, Vapour Pressure and Freezing Point

All these properties of solvent should be low for ease in handling, transportation
and storage.

7.4.10 Toxicity and Flammability

The solvent should be nontoxic, non flammable and of low cost.

7.5 DESIGN OF COUNTER CURRENT MULTISTAGE

EXTRACTOR

Process design of extractor can be divided in the following steps:

(i) Selection of suitable solvent and determination of liquid-liquid equilibrium
data. Actually both these steps are interrelated.
(ii) Determine the minimum amount of solvent required for the desired separa-
tion.
(iii) Determine or decide the actual amount of solvent. Actual amount of sol-
vent must be the optimum amount of solvent. Then complete and finalise
the material balance.
(iv) Determine the number of theoretical stages (for stage wise extractor) or
number of transfer units (for differential continuous contact extractor) re-
quired for the desired separation.
(v) Find the tower diameter of tower type extractor or carry out the process
design of agitator for agitated vessel type extractor and also decide the
height and diameter of agitated vessel.
(vi) Find the stage efficiency for stage wise extractor or height of transfer units
for differential or continuous contact type extractor.
(vii) Find the actual number of stages for stage wise extractor or height of tower
for tower type extractor.
(a) First step is explained in previous Sec. 7.4.
(b) Sm: Minimum amount of solvent is the maximum amount of solvent for
which infinite number of stages are required for desired separation.

F *2 Av/H p > Final

Feed
Process Engineering Channel

Xf Stage X, Stage Avp-I Stage fyp raffinate

n
Final Ei Ei EN N $
El
—z—Solvent
extract % Np
Fig. 7.1 Multistage Counter Current Extraction

F + Sm - Elm + RNp (7.4)

RnP ~ Sm = F ~ Elm = SR,,,

@ProcessEng

(7.5)
ARm is a difference point. It represents net flow outward at the last stage Np
and is equal to net flow inward at first stage. On an equilateral triangular
coordinates, when operating line from AR matches with tie line, infinite number
of stages are required for the desired separation. To find Sm, extend the tie lines
and allow them to intersect SRnp- A line joining the equilibrium compositions of
extract and raffinate phases is called a tie line.
 Introduction to Process Engineering and Design

Among all such points, a point that is farthest from S, if all points are on the
left hand side of 5 or a point which is nearest to S, if all points are on the right
hand side of S, represents ARm, the difference point for minimum solvent.

Ci El m

(a) ARm Nearest from S for m < 1

AR,
(b) ARm Farthest from S for m > I

Fig. 7.2 Minimum Solvent for Counter Current Extraction4

In most of the cases but not in all cases, tie line which is on extension passes
through F gives the location of ARm. After finding the location of ARlir locate

E]m. Draw the line EUnRNp which intersects line FS at XMm.

F+ = Mm (7.6)
Process Engineering Channel

FXf + ^ = XMm Mm = XUm (F + 5m) (7.7)

By substituting the value of XMm from the graph, one can find 5m using
Eq. (7.7).
If A and B are insoluble liquids or can be considered as insoluble liquids at
operating temperature and in desired concentration change, then solute balance
is given by following equation.
@ProcessEng

A(x^-x^) = B{'yl'-ors') (7.8)

where.

kg of solute (C) kg of solute (C)

^= and f/' =
kg of nonsolute (A) kg of solvent (B)
 Design of Liquid-Liquid Extractor

n-
c
r

r.
x;

Fig. 7.3 Determination of Bn

A yx'-o's
(7.9)
B x; -

A r,; -fs
(7.10)
B., Xp - XNp
where, Bm = Minimum amount of solvent
fT] ^ is an equilibrium with Xp. From equilibrium data, one can find |X| * that is in
equilibrium with X'F. Then from Eq. (7.10), one can find Bm. Operating line
starts from point {x^p.fs)-
(iii) To decide the actual amount of solvent, find the number of theoretical
stages required for the desired separation for the different values of actual amount
of solvent, like
5=1.1 5„„ 5 = 1.2 Sm, 5 = 1.3 Sm and so on.
On increasing the values of S from Sm, value of N will decrease. In initial
Process Engineering Channel

range, N will significantly decrease with increase in 5, but after a certain increase
in 5, N may not decrease appreciably.
For example, in this case (Fig. (7.4)) one can say optimum value of 5 is very
close to 1.4 Sm.
Ideally actual amount of solvent = 5opt
But to find optimum values of 5 detailed costing calculations are required.
(iv) How to find number of theoretical stages for desired separation N from
@ProcessEng

the value of S\
(a) If A and B are not completely insoluble liquids:
Refer Fig. (7.1).
 332 Introduction to Process Engineering and Design

1.5
1.45
1.4 (5.5,1.4)

s'.

1.2

10 15 20
A;
Fig. 7.4 Determination ofSiopt

Overall Material Balance.

F+S = E/ + RAip (7.11)
Solute balance:
FXp + = E/^K/ + XNp RNp — MXm (7.12)
F - Ej = Rnp - S = AR = Net Bow outward - Net flow inward (7.13)

F. XcS+

M
Process Engineering Channel

\R

Fig. 7.5 Determination of Operating Curve

Procedure:
FXf + Sfs —
' ^ocate P0'nt M on
@ProcessEng

Find = f+$ graph which lies on FS line.

Extend the line RNp, M that will intersect the binodal curve at Ev Draw
< >
the lines E) F and RNpS. These will intersect at the point AR. Draw the
random lines from AR that give the points of operating curve {Xs, fXs+ j).
 Design of Liquid-Liquid Extractor 333 |

-Equilibrium curve

Operating curve

•r<5+1

X X

Fig. 7.6 Determination of Equilibrium Stages

Operating curve starts from point (X}.-, 5*/) and terminates at point (X^,,
Start the stagewise construction from (XJr, yj) to (Xj^p, JQ in between equi-
librium curve and operating line and find number of theoretical stages, re-
quired for the desired separation.
(b) If A and B are immiscible liquids then overall material balance will be

AiX^-X^) = B(!/l'-ys') (7.14)

By using Eq. (7.14), for the given actual amount of solvent B and its com-
position y/, one can find Operating line starts at {Xp —%') and ter-
,
minates at {x'Np, ys').

{X'F, X,')

Equilibrium
Distribution
Curve
Process Engineering Channel

Operating Line
A
Slope = A/B
@ProcessEng

^s
{X'Np, <)

Xf
r
Fig. 7.7 Counter Current Extraction with Insoluble Solvent
 Introduction to Process Engineering and Design

Stagewise construction starts from point. and terminates at the

point {X'NF,ys') of the operating line.
In a special case, where equilibrium curve is also the straight line then the
number of theoretical stages required for the desired separation can be
obtained from Eq. (7.16 a), or Eq. (7.16 b) (Ref. 3).
ry'
m = =!—^ = slope of equilibrium curve

Ratio of the slope of equilibrium curve to the slope of operating line is

given by following equation.

m'B
e= (7.15)
A
If, e* 1

X'p-^/m'^
In 1-- +-
X'np -y//m'
N= (7.16 a)
Ins

When, £ = 1

Xp-y'lm'
N= -1 (7.16 b)
X'NP -ys'Im'

Multistage counter current extraction requires less number stages for the given
amount of solvent than the cross current extraction or it requires less amount of
solvent for the fixed number of stages than cross current extraction.
Number of Transfer Units (Ref. 3)
In case of differential or continuous contact type extractor, instead of number of
theoretical stages, number of transfer units are determined. Then the working
height of continuous contact type extractor is given by equation
Z = NIHI (7.17)
where, N, = Number of transfer units
//, = Height of transfer units
Number of overall mass transfer units based on raffinate phase is given by equa-
Process Engineering Channel

tion.

dX 1 - XNp ^ Xnp (r — 1) + 1
AU= 1 + —In + —In (7.18)
2 I-XF 2 Xp (/ - 1) + 1
xNP x-x
where, X- = Mass fraction of solute in feed
XNp = Mass fraction of solute in final raffinate
@ProcessEng

r = Ratio of molar masses of non solute to solute

X* = For any point {Xa, of operating curve. X* is the value of X that is
in equilibrium with
 Design of Liquid-Liquid Extractor 335

Equilibrium Curve Operating Curve

r.

Xa Xa XF
Xn X

Fig. 7.8 Determinaion of Number of Transfer Units

If solute component or fraction of feed (A) and solvent (B) can be considered
as completely immiscible liquid mixture, then it is better to use mass ratio con-
centrations, rather than mass fractions. For this special case N/oR is given by
equation

a-;
c/X' 1 + fXv
NP
J 1- —In (7.19)
/* 2
^X - X I + rx'F

where, ^ = Mass ratio of solute to non solute in feed

X^p = Mass ratio of solute to non solute in final raffinate
X{* = For any point ff/) of operating line X'* is the value of
that is in equilibrium with ffa
r = Ratio of molar masses of non solute to solute
In another special case where operating line and equilibrium curve both are
straight lines, number of overall mass transfer units based on raffinate phase
(Nior) is given by equation.
Process Engineering Channel

Xp 1
In 1-1
X^-Tjlm'
"toR = (if 1) (7.20)
1
I -
@ProcessEng

or
NtoR =
[(Xp -y//m')/(Xw-ys'/m')]-\. (if£ = 1) (7.21)

m'B
where, e= and m =
A X
 Introduction to Process Engineering and Design

Example 7.1
A feed stream having flow rate of 200 kg/h and containing 20 mass % acetic acid in
water is to be extracted at 250C with 400 kg/h of recycled M1BK (Methyl IsoButyl
Ketone) that contains 0.1 per cent acetic acid and 0.01 per cent water. The aqueous
raffinate is to be extracted down to 1 per cent acetic acid. How many theoretical stages
will be required and what will the extract composition be? Extraction is to be carried
out in counter current manner.

Table 7.1 Equilibrium Data of Water - Acetic acid - Methyl Isobutyl Ketone at 250C

Mass % in Raffinate Mass % in Extract

Water Acetic acid MIBK X Water Acetic acid MIBK ■f
98.45 0 1.55 0 2.12 0 97.88 0
95.46 2.85 1.7 0.0299 2.8 1.87 95.33 0.0196
85.8 11.7 2.5 0.1364 5.4 8.9 85.7 0.1039
75.7 20.5 3.8 0.2708 9.2 17.3 73.5 0.2354
67.8 26.2 6.0 0.3864 14.5 24.6 60.9 0.4039
55 32.8 12.2 0.5964 22 30.8 47.2 0.6525
42.9 34.6 22.5 0.8065 31 33.6 35.4 0.9492

(Table 15.1 of Ref. 3)

= mass ratio of solute to diluent (CM) in raffinate phase
f/ = mass ratio of solute to extraction solvent (C/6) in extract phase

AcOH

F M
Process Engineering Channel

Np
H,0 MIBK ^

Fig. 7.9 Ternary Diagram for AcOH-H^O-M/BK System 3

Solution:
F + S =E,+Rnf = M (7.11)
200 + 400 =M = 600 kg/h
@ProcessEng

FX,. + 8%
-*m =
F +S

(200x0.2)+(400x0.001)
= 0.067 33, fT, = 0.088
600
(From Fig. 7.9)
 Design of Liquid-Liquid Extractor

MAm - Ej^xj + -^v/' RNP

40.4 = 0.088 (600 - RNP) + 0.01/?,w
Rnp = 158.97 kg/h, E, = 441.03 kg/h
Random lines from AR give the points of operating line (X., ,).
A; 0.2 0.14 0.08 0.065 0.01
X+, 0.085 0.06 0.035 0.025 0.001
Equilibrium data:
X 0 0.0285 0.117 0.205 0.262 0.328 0.346
o* 0 0.0187 0.089 0.173 0.246 0.308 0.336
Stepwise construction from 4^,- (X. corresponds to Xp) to XNP gives number of theoreti-
cal stages required for desired separation.
From graph, N = 4.62

0.3J

0.2^
r
Enlarged View

0.1-
N= 4.62

(0,0) 0.2 0.3

X
Fig. 7.10 Determination of Number of Stages for Example 7.1

Example 7.2
Solve Example 7.1 considering M1BK (B, solvent) and water (A, non-solute compo-
nent) of feed as completely immiscible liquids and equilibrium curve as a straight line
Process Engineering Channel

in terms of mass ratio concentrations.

Solution:
Overall solute balance

A(x;-X^P) = B(rlf-7^s,) (7.14)

A = 200 (1 - 0.2) = 160 kg/h
B = 400 (1 - 0.001) = 399.6 kg/h
@ProcessEng

x;= — = 0.25 X'=— =0.0101

f NP
80 99

O''=9 ry '= 0.1

= 0.001
4
(100-0.1-0.01)
160 (0.25 - 0.0101) = 399.6 (%'- 0.001)
 Introduction to Process Engineering and Design

kg acetic acid
% = 0.097 —
kg M1BK

Xp = 0.25,
For operating range Y < 0.25 slope of equilibrium curve

n-|I/3
0196 ' x f 0^039 .
0.2354 ^
x = 0.7571
L10.0299 0.1364 0.2708 )

e = = 0.7571 x = 1.89
A 160

X'F - Y'hn'
In i-i + i
X^-Ys'lm' £
N= (7.16 a)
In e

0.25-(0.001/0.7571)
In 1- +
0.0101-(0.001/0.7571) 1.89 1.89
N=
In 1.89

/V = 4.13

Example 7.3
For the extraction, described in Example 7.1, calculate
(a) NtoR considering MIBK and water as partially miscible liquids.
(b) NioR considering MIBK and water as completely immiscible liquids and equilibrium
curve as straight line (in terms of mass ratio concentration).
Solution:
(a) Number of overall mass transfer units based on raffinate phase is given by equation

XF l-X NP
dX 1 . Xnp (r - 1)
N,„R= J + —In + — In (7.18)
XNp X - X * 2 l-x. 2 XF{r-\) + l

d)r = 0.2, XNp = 0.01

Process Engineering Channel

Data for equilibrium curve:

X 0 0.0285 0.117 0.205 0.262 0.328 0.346
iT 0 0.0187 0.089 0.173 0.246 0.308 0.336
Data for operating curve:
0.2 0.14 0.08 0.01
s+ I 0.085 0.06 0.035 0.001
@ProcessEng

Table 7.2 Data for Finding NtoR [from Fig. (7.11)]

X 0.2 0.15 0.1 0.05 0.025 0.01

A* 0.113 0.089 0.063 0.032 0.014 0.001
X-X* 0.087 0.061 0.037 0.018 0.011 0.009
IdX-X*) 11.494 16.393 27.027 55.555 90.909 111.111
 Design of Liquid-Liquid Extractor 339

0.3-

<
O
■C
aj -S
Q, 0.2
cj "" S?
< T= .0
^ .y
5 ^
O c Ox
.^Z. (1^
o >
2 o
00
0.1
iZ
v. C

09

0,0 0.2 0.3

Mass Fraction of AcOH

in Water Rich Phase
Fig. 7.1 I Equilibrium Data for AcOH - Water - MIBK System

0.2
dX
From Fig. (7.12), j = 1.7236 square units = 7.0351 (Integral value)
o.oi X — X

120-

00-

80-

1 60-
x-x*
40-
Process Engineering Channel

20-

0,0 0.01 0.05 0. 0.15

X
Fig. 7.12 Determination of N(oR
@ProcessEng

Molar mass of nonsolute [g

r= = 0.3
Molar mass of solute 60

(1-0.01 0.01(0.3-1) + !
W„s=7.0351 + An + — In
1-0.2 2 0.2 (0.3 - 1) + 1
NioR = 7.0351 + 0.106 55 + 0.0719 = 7.213 55
 Introduction to Process Engineering and Design

(b) If water (A) and MIBK (B) are immiscible liquids and equilibrium curve is straight
line (in mass ratio concentration) for the given operating range

x'F -yjim'
In + i
1
x-NP-y* " ' 1 £j £
U,oR = (7.20)
i-

kg of Acetic acid
0 0.0299 0.1364 0.2708
kg of water

kg of Acetic acid
0 0.0196 0.1039 0.2354
kg of MIBK

1/3
00196 WO. 1039 0.2354
Xp =0.25,/??' = x
0.0299 ) V 0.1364 0.2708 J
= 0.7571

£ = W = 0.7571 x = 1.89
A 160

0.25 -(0.001/0.7571)
In +
0.0101-(0.001/0.7571) 1.89 1.89
U.oR =

HrfeU

= 5.584

Example 7.4
For the separation of dimethylformamide (DMF) from its dilute solution in water, liq-
uid-liquid extraction may require lower operating cost than atmospheric distillation.
Methylene chloride is considered to be the best solvent for extracting DMF from its
aqueous solution.
Process Engineering Channel

DMF-water solution having a flow rate of 1000 kg/h and containing 20% DMF by
mass is to be counter currently extracted with methylene chloride to reduce the DMF
concentration to 1% in the final raffinate. Determine (a) the minimum amount of solvent
which can be used and (b) the number of theoretical stages if actual amount of solvent is
double than the minimum required.
Data: Phase equilibrium equation5 is given by equation 0.5555 A'at 25° C where,
jpand A'are mass fractions of solute.
@ProcessEng

Solution:
Mutual solubilities of water (A) and methylene chloride (5) in each other at room
temperature are very low. Hence, to simplify the calculations, water (A) and methylene
chloride (B) may be assumed as completely insoluble liquids.
(a) For completely immiscible liquids, solute balance is given by the equation

A w-xWWW) (7-14)
 Design of Liquid-Liquid Extractor 341

0.16 -

-Vim = 0.125

(xF, r;)

X'f=0.25

(0,0) 0.04 0.08 0.12 0.16 0.20 0.24 0.28

X'
Fig. 7.13 Determination of Equilibrium Stages for Example 7.4

Table 7.3 Determination of Data for Equilibrium Line

fTO 0.013 89 0.0278 0.042 0.055 55 0.0694 0.0833 0.1111 0.1389 0.166 65
X 0 0.025 0.05 0.075 0.1 0.125 0.15 0.2 0.25 0.3
X 0 0.014 0.0286 0.04384 0.0588 0.0746 0.09 0.125 0.1613 0.2
X 0 0.0256 0.0526 0.081 0.1111 0.1429 0.1765 0.25 0.3333 0.4286

=
From graph fu,, 0.125 [From Fig. (7.13)]
Solute balance:

A iXF-XFP) = Bm(7-l'm-7-s')
A - F(l - XF) - 1000 (1 - 0.2) = 800 kg/h, X^P = 0.01/0.99 = 0.0101
800 (0.25 - 0.0101) = Bm (0.125 - 0)
Bm = 1535.36 kg/h
(b) Actual amount of solvent B = 2x 1535.36 = 3070.72 kg/h
Solute balance:

A(XP-X^P) = B(0ri,-'rs')
Process Engineering Channel

800 (0.25-0.0101) = 3070.72 (F,0)

X,' =0.0625
From Fig. 7.13, N - 3.85
If equilibrium curve is considered as a straight line in terms of mass ratio concentra-
tion, then number of theoretical stages required for desired separation is given by following
equation
@ProcessEng

N= (7.16 a)
In £
 Introduction to Process Engineering and Design

m 'B
£=
A

1/4
IY 0.014 3 ( 0.04384 3 ( 0.0746 3 (0.16131
m =
Lv0.0256 j I 0.081 J 10.1429 7 10.3333 j
m = 0.523

0.523 x 3070.72
£= =2
800

25
In IY^ l-il+i
[lo.oioi 2 2
N=
In (2)

N= 3.687

Example 7.5
For the liquid-liquid extraction system, given in Example 7.4, calculate NtoR for the
actual amount of solvent B = 2 Bm.
Solution:
Water (A) and methylene chloride (B) are considered as completely immiscible liquids.
Also, as shown in Fig. 7.13, equilibrium curve is a straight line in terms of mass ratio
concentration. With these assumptions, formula for finding Nlol< is

x'F -<ys'lm' 1
In 1- + i
x m £
np ~
NIoR = (7.20)
1-1

B = 2Bm = 3070.72 kg/h, A = 800kg/h, x/ =0.25, 7,' =0, 0.523

0.523 x 3070.72
£= = 2, X^p =0.0101
800
Process Engineering Channel

0.25-0 n.+-
i
In i--
0.0101-0 2 2
NwR =
i-i
2

NtoR = 5.11
@ProcessEng

7.6 INDUSTRIALLY IMPORTANT EXTRACTORS

Many types of extractors are available for achieving mass transfer (Ref. 3,4, 6, 7,
8, 9) each has its own particular advantage. As per general classification, there
are two fundamental types of extractors; stagewise and differential. The stagewise
extractors consist of discrete units, in each of which the phases are brought into
 Design of Liquid-Liquid Extractor

contact, mixed, allowed to separate and sent to next unit. Differential extractors
provide continuous contact and mass transfer along the full length of the device
and phases are separated only at the end.

7.6.1 Industrially Important Extractors can be Divided

into Four Major Categories

(i) Mixer-settlers (stage wise)

(ii) Unagitated columns (differential)
(iii) Agitated columns (differential)
(iv) Centrifugal extractor (differential)
Operation, construction and design of different extractors are given in various
books like Mass Transfer Operations by Treybal (Ref. 4), Perry's Chemical En-
gineers' Handbook (Ref. 3), Unit Operations by G .G. Brown (Ref. 7), etc.
Design of a few type of extractors are discussed here.

7.6.2 Design of Mixer-Settler

(a) Mixer-settler type extractors have the following advantages over other type
of extractors.
(i) Provide better contacting of extract and raffinate phases and provide
higher rate of mass transfer.
(ii) Higher efficiency or attain separation closer to equilibrium.
Process Engineering Channel

Mixer
@ProcessEng

□ ^ [3- Turbine Agitator

-Baffle

Fig. 7.14 Baffled Mixing Vessel

 Introduction to Process Engineering and Design

(iii) Reliable scale-up.

(iv) Requires low head room.
(v) Low fixed cost.
(vi) Provides more flexibility stage wise.
(b) These type of extractors have the following disadvantages over other types
of extractors.
(i) Require large hold up.
(ii) Require high power cost.
(iii) High solvent inventory.
(iv) Require large floor space, etc.
If number of theoretical stages required for desired separation is less than or
equal to four, mixer-settler is probably the most economical among all types of
extractors. For this application, turbines and propellers are used as agitators.
Among all type of agitators, pitch blade turbine agitator [refer Fig. 10.2 (iv)] are
found to be most effective for mixing of two immiscible liquids. For smaller
agitated vessel mixer propellers are selected. For large mixers, turbines are se-
lected.

7.6.3 Process Design of Mixer

It includes two steps:

(i) Determining the volume of the mixer.
(ii) Process design of agitator; e.g. deciding shape, factors and power require-
ment.
(i) Mixer settlers are operated in batch wise mode and also in continuous man-
ner. For batch mixer, volume of mixer is decided by the total volume of
liquid mixture, charged to the mixer. For continuous mixer, volume of the
mixer depends on hold up time.
Ideally, holdup time in a continuous mixer is the time required to reach
equilibrium. It also depends on the rate of mass transfer. It can be decided
on the basis of pilot plant or lab scale experiments of the given system.
(ii) Process Design of Agitator (Ref. 1 and 10)
The work of Miller and Mann and of Olney and Carlson have established
that to calculate power required for agitating two liquid phases one can use
Process Engineering Channel

the power data available for agitating single phase liquids, if density and
viscosity of two phase liquid mixture are determined by following equa-
tions.
+
Pav - Pc Pd (7.22)

Pc y + l-^PpZ/)
Pav = — (7.23)
z
@ProcessEng

c Pp + PC
3
where, p = Average density of two phase liquid mixture, kg/m
■j
pc = Density of continuous phase, kg/m'
pD = Density of dispersed phase, kg/m'1
Z = Volume fraction of appropriate phase
pc = Viscosity of continuous phase, cP or mPa • s
pD = Viscosity of dispersed phase, cP or mPa • s
 Design of Liquid-Liquid Extractor

100
60
40
2.3
20
/4
0

0.6
0.4
0.2

68 68 6 8 68
10 102 1o 3
104

"'K n
Re
v
3
Fig. 7.15 Agitator Power Correlations .
Curve: I Six Flat Blade Turbine, Da/Wi = 5, Four Baffles Each DT/I2, ( Refer Fig. 10.2 (v))
Curve: 2 Six Flat Blade Open Turbine, DJW = 8, Four Baffles Each Equal To Dj/12,
(Refer Fig. 10.2 (ii)
Curve: 3 45° Pitched Blade Turbine. Da/Wi = 8. Four Baffles. Each DT/I2. (Refer Fig. 10.2 (iv).
But with six blades)
Curve: 4 Propeller Pitch Equal To 2Da, Four Baffles. Each DT/I2. (Refer Fig. 10.2 (i))
Curve: 5 Propeller Pitch Equal To Da, Four Baffles, Each DT/I0. (Refer Fig. 10.2 (i))
(Reproduced with the Permission of McGraw-Hill Education. U.S.A.)

Dispersed phase is a liquid phase which forms the droplets and are dis-
persed in a continuum of the other. Other phase is called continuous phase.
Ordinarily the liquid flowing at the smaller volume rate in the extractor will
be dispersed in another. For batch operation, the liquid in which the impeller
is immersed when at rest is usually continuous. Normally dispersed phase
has higher viscosity and lower interfacial tension. In continuous extraction
Process Engineering Channel

interchanging of dispersed phase and continuous phase is possible.

Power data for agitating single phase liquids in baffled vessel are avail-
able in the form of graph Np vs Re [Fig. (7.15)]. The same can be used to
calculate the power required for mixing two phase liquid mixture.

Pgc
(7.24)
"P =
3
@ProcessEng

Pav " D#

nDfp
Re = (7.25)
Pav
where, Nn - Power number
Re = Reynolds number
 346 Introduction to Process Engineering and Design

P = Power required for agitation, W

gc = Newton's law of gravitational constant, (g(,= 1 for SI system)
n = Impeller rotational speed, s_l
Da - Impeller diameter, m
=
Pav Pav Density and viscosity of two phase liquid mixture, can be
determined by Eqs (7.22) and (7.23), respectively.

7.6.4 Process Design of Settlers (Ref.: 3, 4, II)

Settlers are also known as decanters. They are used to separate two immiscible
liquids or two partially miscible liquids. The mixture of liquids leaving a mixer,
is a cloudy dispersion which must be settled, coalesced and separated into its
liquid phases. It requires sedimentation and coalescence of the drops of the dis-
persed phase. Decanters used are of the various shape as shown in Fig. (7.16). It
can be horizontal or vertical.
Volume of settler is estimated by taking hold-up time equal to 5 to 10 min.
Laboratory experiments for deciding hold-up lime could prove valuable.

Siphon
breaks r
W Sw

Dispersion it
(Feed)

I 1
Heavy Light
Baffles liquid liquid

(a) Horizontal Gravity Settler

Vent
Process Engineering Channel

Heavy
fri8hW
liquid Interface liquid
take-off Dispersion
V///////////////////. take-off
^(Feed)

N
N
@ProcessEng

Datum
(b) Vertical Gravity Settler
Fig. 7.16
 Design of Liquid-Liquid Extractor

Diameter or size of the decanter is decided on the basis of fact that velocity of
continuous phase should be less than settling velocity of the droplets of dispersed
phase. Velocity of continuous phase is calculated by equation;

u.. = — < u d (7.26)

A
where.
u = Velocity of continuous phase, m/s
Lc = Continuous phase volumetric flow rate, m /s
A, = Area of interface, m"
ud = Settling velocity of the dispersed phase droplets, m/s
Stokes law is used to determine the settling velocity of the droplets.

dd8(Pd-Pc)
Ud = (7.27)
18 AC

where, dd = Droplet diameter, m

ud = Settling velocity of the dispersed phase droplet, m/s
g = Acceleration due to gravity = 9.81 m/s2
-j
pc = Density of continuous phase, kg/nr
pd = Density of dispersed phase, kg/m3
pc = Viscosity of continuous phase, N • s/m2 or kg/(m • s)
Droplet size (dd) can be assumed equal to 150 pm. In decanter, feed droplet
sizes are normally well above 150 pm. If the calculated settling velocity is greater
than 4 x 10 m/s, then a figure of 4 x 10 m/s is to be used.
For vertical decanter, take L = 2 D,, thickness of dispersion band = 0.1 L and
residence time of droplets in the dispersion band = 0.1 L /ud. The residence time
of droplets in dispersion band should be 2 to 5 min.
For a horizontal cylindrical decanter, the interfacial area A,- depends on the
position of the interface.
A - = WL (7.28)

W =2yj2rZ -Z2 (7.29)

Process Engineering Channel

Area of interface A \ = W- L
@ProcessEng

— I "H -{Z-ry

Fig. 7.17 Geometry of Horizontal Separator

 348 Introduction to Process Engineering and Design

where, W = Width of interface, m

Z = Height of the interface from the base of the vessel, m
L = Length of cylinder, m
r = Radius of cylinder, m
In the approximate method, for horizontal decanter,

take LIDj = 4 and D = 8.4 ^qc + qd (7.30)

where, D = Inside diameter, m

qd, qc = Volumetric flow rate, nr/s (for horizontal decanter)

Example 7.6
For the extraction system described in Example 7.1, design a mixer-setter type extractor.
Following data are obtained from pilot study.
(i) Residence time (hold-up time) of liquid mixer in pilot plant mixer, 6=6 min
(ii) Stage efficiency = 0.92
(iii) Type of agitator = 45° pitch blade turbine
(iv) Shape factors of pilot plant mixer: DJWj = 8. four baffles, D// = 12, six blades,
HIDt = [,Da/Dt= 0.33
where, Da = Diameter of agitator, m
Dt = Inside diameter of mixing vessel, m
J = Width of baffle, m
H = Depth of liquid tank, m
Wj = Width of agitator blade, m
(v) Power required per unit volume in pilot plant = 220 W/nf
Solution:
Treybal1 demonstrated that for geometrically similar agitated vessels with equal holding
time and equal power per unit volume on the two scales, the stage efficiency is likely to
increase on scale-up. Based on this proposition, residence time in commercial scale
mixer is 6 min and stage efficiency is 0.92.
Total number of mixer settler = 4.62/0.92 = 5
Working volume of mixer = Hold up time x Volumetric flow rate of liquid mixture
Vw = exqv
qv = (mass flow rate of feed + mass flow rate of final extract)/pav
—
Process Engineering Channel

Pav Pc Zc Pn Z[)
Pmibk = 801 kg/m3, pwater = 1000 kg/m3, pAceticacid = 1049 kg/m3
This mixer-settler will be operated in continuous manner. If 1SI mixer is considered,
then extract phase (MIBK rich phase) is the lighter phase and feed (water rich phase) is
the heavier phase.

X
Pf=7 - (7-31)
VV'l Wj
@ProcessEng

Pi P2

where w,, VV2 = Mass fractions,

Pi, P2 = Densities of components
 Design of Liquid-Liquid Extractor

pF = = 1009.4 kg/m3
0.2 | 0.8
1049 1000

pF = = 821.36 kg/m3
0.088 | 0.892 | 0.02
1049 801 1000
Density of extract. p£ = 821.36 kg/m3
Volumetric flow rate of feed = 200/1009.4 = 0.198 m3/h
Volumetric flow rate of final extract = 441.03/826.36 = 0.5337 m3/h
Final extract is having higher volumetric flow rate than feed. Hence, feed or water-
rich layer is the dispersed phase and final extract (solvent rich layer) is the continuous
phase.

200/1009.4 =027

200 | 441.03
1009.4 821.36
Zc=l-Zd = 0.73
pav = pc Zc + pD ZD = 821.36 x 0.73 + 1009.4 x 0.27 = 872.13 kg/m3
qv = (200 + 441.03) / 872.13 = 0.735 m3/h

H
— = 1, 6 = 0.0735 m,3
V =0.735—-
Di 60

-DlH =0.0735
4 T

^D3 = 0.0735 m3

DT = 0.454 m
For 45° pitch blade turbine, DJDr = 0.33, where D(l = diameter of agitator, m
Da = 0.1498 m
Power required per unit volume = 220 W/m3
P = 220 x 0.0735 = 16.17 W
For 1st trial calculations, let tip velocity of agitator, v = 200 m/min = nDan
Process Engineering Channel

kx 0.1498 x n = 200
n = 424.98 rpm - 425 rpm
For pure components pMIBK = 0.5 mPa • s, pwaler = 0.8 mPa • s, pAcetic acid =1.1 mPa • s

I Wj W7 VV3
p, p2 p,

1 0.088 0.02 0.892 . OC)A

@ProcessEng

= 1 1 = l.ooV
pc, 1.1 0.8 0.5
pc = 0.5294 mPa • s
W vv
I AA , watcr O7 no
— = + = + = 1.1818
PaA /'water 1.1 0.8
 Introduction to Process Engineering and Design

Hd = 0.846 mPa • s

0.5294 1.5x0.27x0.846
A^av = 1+ = 0.9059 mPa • s
0.73 (0.846 + 0.5294)

nDj:p,v (425/60) x 0.14982 x 872.13

Re = —a-^- = = 153 025
-3
A'av 0.9059x10

Np = I -5 [From Fig. (7.15)]

= 1.5
D
Pay"' a

' 425x3
1.5 x 872.13 x x 0.1498
60
P=
1
P = 35 W >> 16.17 W
Hence, decrease the value of tip velocity to match this value.
Let for second trial calculation, tip velocity = 155 m/min

155
n = = 329.36 rpm - 329 rpm
(tt x 0.1498)

329
Re = 153 025 x = 118 459
425
N = 1.5 (From Fig. 7.15)

329
1.5 x 872.13 x x 0.1498
60
P= = 16.27 W

This is close to 16.17 W.

Use 45° pitch blade turbine, having diameter Da = 0.1498 m and rotational speed,
n = 330 rpm.
(b) Process design of settler;
(i) Let position of settler be horizontal.
Process Engineering Channel

Approximate diameter of horizontal settler

D = 8.4 -jqc+qd (7.30)

441.03/3600
C
lc = = 1.4825 x 10"1 m3/s
826.36
@ProcessEng

200/3600
<ld = = 5.503 82 x K)"5 m3/s
1009.4

D = 8.4 qc + qd = 0.1197 = 0.12 m

This equation is valid for L/D, = 4.

 Design of Liquid-Liquid Extractor

Length of horizontal decanter L = 0.48 m

D and L by other method:
Settling velocity of the droplets of dispersed phase

djgiPd -Pc)
U.i = (7.27)
18 Pc
dd = 150 x 10-6 m. g = 9.8 m/s2, pd = 1009.4 kg/m3
pc = 821.36 kg/m3, pc = 0.5294 mPa • s

(150 x lO-6 )2 x9.81 x( 1009.4-821.36)

ud =
-\-3
18x0.5294x10"

= 0.004 355 m/s

Lc _ qc _ (0.5337/3600)
A min = = 0.034 m2
u
d u
d 0.004 355
W L
Anin = ( i )mn
If the position of interface is fixed at the centre line of settler then VP, = £),, let L = 4D,.

A™, = 4 fl,2 = 0.034 m2

Dimin = 0.0922 m < D,- = 0.12 m, L = 0.48 m
To fix the position of interface at centre line of decanter Z( = D/2, locations of outlet
nozzles can be determined based on the pressure balance.

Vent

Feed

Light liquid
Heavy liquid

2/ A/)
Process Engineering Channel

Fig. 7.18 Location of Nozzles for Horizontal Decanter

Pressure balance:
(Zf, - z,) Pi, = (z, - z,) pL
ph = density of heavier phase = 1009.4 kg/m3
pL = density of lighter phase = 821.36 kg/m3
@ProcessEng

Zj = D/l = 0.12/2 = 0.06 m

Let z, =0.8 D(. = 0.8x0.12 m = 0.096 m
(zh - 0.06) x 1009.4 = (0.096 - 0.06) x 821.36
zh = 0.0893 m
 Introduction to Process Engineering and Design

(b) Vertical decanter (other option)

A-min = (^/4) ^min= 0.034 m2

D/min = 0.208 m
Let Di = 0.25 m L = 2 x 0.25 = 0.5 m
Width of dispersion bend = 0.1 L = 0.05 m
Residence time of the droplets of dispersed phase in dispersion band,
0.05 0.05
e= = 11.481 s
0.004 355
As per the guidelines, this should be at least 120 s. For 120 second residence time,
L = 5.226 m (very high). This guide line is given for higher flow rates (1500 kg/h to 600
kg/h).
Hence, let Di = 0.25 m and L = 1 m which means 0 = 23 seconds.
To fix the interface at the centre of vertical decanter, locations of nozzles must be
determined.

Light liquid
Heavy liquid

Feed
Process Engineering Channel

Fig. 7.19 Location of Nozzles for Vertical Decanter

Pressure balance:
(z^Zi) PL8 + ZiPhg = zhphg
, , PL ,
Zh = (z/ - zt) — + Zi
Ph
Zj = 0.5 m, Z[ = 0.9 L = 0.9 m
@ProcessEng

mn - 0.5)
z.h = (0.9 ncx x 821.36 + nc
0.5 = nonce
0.8255 m
" 1009.4
Two criteria may be used for scale-up of agitated vessel; (a) constant tip velocity and
(b) constant power per unit volume.
 Design of Liquid-Liquid Extractor 353

Criteria of constant tip velocity is used for miscible liquids where heat is transferred
from coil or jacket or where suspended solids are involved.
Criteria of constant power per unit volume can be used for immiscible liquid systems
gas-liquid systems, emulsions and pastes.

7.6.5 Process Design of Packed Tower Type Extractor

(Ref.: 3, 6, 7, 8)

In packed tower type extractor, standard commercial packings, used in vapour-

liquid system, are used. This includes structured packings, Raschig and Pall rings,
Berl and Intalox saddles and other random packings. Packing reduces the verti-
cal back mixing of the continuous phase and thereby reduces height required for
mass transfer. It is recommended to redistribute the dispersed phase at about
every 1.5 to 3 m distance to generate new droplets. Size of packing should pref-
erably be less than one-eight of the tower diameter to minimize the wall effect.
Flooding velocity in packed tower is the velocity of dispersed phase or continu-
ous phase at which dispersed phase is coming out from the outlet pipe of continu-
ous phase or vice versa.
(a) Tower diameter: Diameter of packed tower is determined based on value of
flooding velocity. To find the flooding velocity in packed tower many
correlations are available. One of the best correlations; Crawford-Wilke
correlation, is represented in Fig. 7.20.

60,000
40,000

20,000

10,000
41 *
6000

a I 4000
2000

*•11 1000
Process Engineering Channel

L 600

400
200 \

100
4 6 10 20 60 80 100 200 400 1000
@ProcessEng

[li> +v
<>: ]' P' 'Crfk )
Fig. 7.20 Flooding in Packed Towers, Crawford-Wilke Correlation3
(Reproduced with the Permission of McGraw-Hill Education, U.S.A.)

where, av. = Interfacial tension of continuous phase, Ibf/ft

gc = Newton's law gravitational constant
= 4.18 x 108 (lb • ft)/(lbf • h2)
 Introduction to Process Engineering and Design

p(, = Density of continuous phase, lb/ft3

fi(. = Viscosity of continuous phase, lb/(ft • h)
Ap = Difference in density, lb/ft3
ap = Specific packing surface, ft /ft
e = Fraction void volume in packed section
vcF, vDF = Superficial flooding velocity, ft/h
Actual velocity of the continuous phase and the same of the dispersed phase
should be less than or equal to 50% of the flooding values.
(b) Height of packed tower: Height of packed lower H is given by equation.

H = NtoR ■ HIoR = NloE ■ HIOE (7.32)

Value of HIoR or HloE must be decided by actual experiments at pilot plant
scale. Value of HloR in packed tower depends on type of system, type of
packings, size of packings, tower diameter, etc. Hence it is difficult to find
the suitable correlation for finding HloR for the given system with the given
type and size of packing and given diameter of packed tower.
For example, equation for finding HloR for acetic acid-water-MIBK
system, in which water rich phase is the raffinate phase and MIBK rich
phase is the extract phase, is given by equation1.

0.648
HIOR = 0.2347 (7.33)

where, HloR = Height of equivalent overall transfer unit based on raffinate

phase, m
vD = Actual superficial velocity of dispersed phased, m/s
vc = Actual superficial velocity of continuous phase, m/s
This equation was derived by Sherwood et al] for the packed tower having
0.09 m diameter, 12.7 mm carbon rings at 250C for the certain range of
flow rates. Hence, the use of this equation for the same system with larger
diameter packed tower, different type and size of packing and for different
values of flow rates, may not be reliable. So the equation of HloR or HloE
must be determined on the same system at pilot plant scale with similar
type of equipment and with similar conditions like same values of superficial
Process Engineering Channel

velocities, same operating temperature, etc. However, Eq. (7.33) may be

used for the preliminary design of the pilot equipment.
(c) Criteria of Selection: If number of theoretical stages required for desired
separation is less and limited floor area is available in the plant than packed
tower can be selected as extractor. Packed tower consumes much less power
than mixer settler.
@ProcessEng

Example 7.7
For the extraction system described in Example 7.1, design the packed tower type ex-
tractor.
(a) Tower Diameter:
Let type of packing: SS Pall rings
Size: 16 mm (for lsl trial calculations)
 Design of Liquid-Liquid Extractor 355

Light
liquid
(Final extract)

Interface

9° oVo0 O0o0o0o0o0o0o*v^®o<,o°o0o'o'
Heavy _ o0 o0o',o0 o'>o',o<>o0o0o0o0o0o<>o0ogogogo
Liquid
(Feed)

— Packing

Light
J
Liquid r
(Solvent) JUUUUUUUUUL
Process Engineering Channel

^Heavy
Liquid
(Final raffinate)

Fig. 7.21 Packed Extraction Tower. Light Liquid Dispersed.

@ProcessEng

From Table 9.2 of Chapter 9,

ap = specific packing surface = 340 m2/m3
e = fraction of void volume = 0.92
To find the flooding velocities, first the value of following function must be determined.
0.2 ,1.5
a
c8c Pc
f= (7.34)
Pc Ap
 356 Introduction to Process Engineering and Design

where, (7C = Surface tension of continuous phase, Ibf/ft

From Example 7.6, volumetric flow rate of feed = 0.198 m3/h
Volumetric flow rate of final extract = 0.5337 m3/h.
Volumetric flow rate of extract is very much greater than the same of feed, hence extract
is the continuous phase and feed is the dispersed phase.
Final extract contains 89.2% M1BK, 8.8% acetic acid and 2% water by mass.
Surface Tension of MIBK:
Structure of MIBK:

CH3 —CH —CH2—CH,

I
c=o
I
CH3

(Molar mass = 12 x 6 + 16 + 12 = 100)

For hydrogen bonded compound, Sugden equation can be used to predict surface ten-
sion.
OU4 = \ 'A (PL-Pg)
where, a = Surface tension, dyn/cm
pL = Liquid density, mol/cm3
\ 'J\ = Temperature independent parachor value
For MIBK.
pL = 801 kg/m3

pM 1 x 100 273
x
Pc
' RT (273 + 30) 1x22.414

pG = 4 kg/m3

103 1 1
pL = 801x x X = 0.008 mol/cm-
6
1 10 10 0

nr=4x-^—x-i-x — = 4 x 10-5 mol/cm3

FG 1 106 100
From Table 3.343, Ref. 3,
= 171.9 + 55.5 + 29 = 256.4
Process Engineering Channel

1/4
(7 = 256.4 (0.008 - 4 x lO"5) = 2.0409
G= 17.35 dyn/cm
For acetic acid,
p, = 1049 kg/m3

pM 1x60 273
Pg = x = 2.41 kg/m3
RT (273 + 30) 1x22.414
@ProcessEng

10 1 1
p. = 1049x x-^-x— =0.017 48 mol/cm3
HL I 10 6
60

5
pr = 2.41 x x —x -j— = 4.016 x 10 mol/cm3
HG 1 106 60
 Design of Liquid-Liquid Extractor

[f] =55.5 + 73.8= 129.3

cr1/4 = 129.3 (0.01748 - 4.016 x K)"5)
o" = 25.86 dyn/cm
For water, (T = 71.4 dyn/cm
Surface tension of liquid mixture is given by following:
1/4 v^l/4 /n T
om = 1(7, a-, (7.35)
where = x, = mole fraction of component i in liquid phase

0.892/100
— —
-^mibk 7 ~ 0-7758
0.088 | 0.892 | 0.02
60 100 18

0.088/60
:=
Xacoh 7/ 7 =0.1276
0.088 | 0.892 | 0.02N
60 100 18

Ah.O = 0.0966

c'" = 17.35"4 x 0.7758 + 25.86l/4 x 0.1276 + 71.4I/4 x 0.0966

(7C = 21.443 dyn/cm
= 0.021 443 N/m
From Example 7.6:
p(. = 821.36 kg/m3, p(. = 0.5294 x KT3 kg/(m • s)
gc = \,Ap = pd-pc=\ 009.4 - 821.36 = 188.04 kg/m3
To use Fig. 7.20 (Crawford - Wilke correlation) all variables must be in US customary
units.

(7, = 0.021 443 x x — = 1.47 x lO"3 Ibf/ft

4.448 22 3.28
g(. = 4.18xl08 lb ■ ft/(lbf ■ h2)

pr = 821.36 x = 51.276 lb/ft3

1.601846x10
Process Engineering Channel

ur = 0.5294 x lO-3 x ]
= 1.28 lb/(ft ■ h)
4.133789 xlO-4

]
Ap = 188.04 x = 11.739 lb/ft3
16.01846

an = 340 m2/m3 = 340 x Q 3048

- = 103.632 ft2/ft3
@ProcessEng

' 1
e = 0.92

1.47 x 10-3 x 4.18 x 108 1°2 f 1.28 Yl03.632Nl-5

f= = 852.81
51.276 11.739 7V 0.92
 Introduction to Process Engineering and Design

From Fig. 7.20 and from Example 7.6,

(vCF + v
df fPc'^P Pc) = 175

175 a
, \n i/7 ,o pPc 175x103.632x1.28
( vcf
L
+v
df )' = = = 452.72 ft/h
pc 51.276

qc = 1.4825 x lO"4 m3/s

qd = 5.503 82 x lO"5 m3/s

vrF 1.4825 xl 0"4

= = 2.6936
vDF 5.503 82 xl 0~5

((2.6936 vdf)i/2+V^)2 =452.72

(2.6412 v'/2)2 = 452.72 x—5—x^^- =0.038 33

3600 1

(2.6412)2 nDF = 0.038 33

vDF
V =
DF =0.0055 m/s and vCF = 0.0148 m/s
^
Let actual velocities be
vc = 0.5 vCF and vD = 0.5 vDF
vD = 0.002 75 m/s, vc = 0.0074 m/s

VC
(n/4)Df

1 4825XlrJ
—Dr - - = 0.02 m2
4 0.0074
/), = 0.16 m
Let D, = 0.2 m
Revised values of actual velocities based on final value of inside diameter.
vc = 0.0047 m/s, vD = 0.001 75 m/s
Height of packing:
Process Engineering Channel

Total height of packing H = NtoR ■ HloR

NlnR = 7.213 55 (From Example 7.3)
HioR for the given system
Huk = 0.2347 (vc/vDfm
Where HloR is in m.

^ 0.0047 ^■648
@ProcessEng

HloR = 0.2347 = 0.4452 m

v. 0.00175 s
H = 1.213 55 x 0.4452 = 3.211 m
Results: Type of packing: 16 mm, SS Pall rings, inside diameter of tower: 0.2 m, total
height of packing section = 3.2 m
 Design of Liquid-Liquid Extractor

7.6.5.1 How to Find HtoR or HtoE from Experiment (Ref. II, 12)

To find the HloR from the experiment at pilot plant or at lab scale, one can use the
following equation for the packed tower type extractor.

Superficial velocity of raffinate ^ ^

"toR
Kro KRQ
where, KRa Overall mass transfer coefficient based on raffinate phase

kmol of solute transfered/second

Kro
volume of packing x AC, m

AClm Logarithmic mean driving force

V£
Similarly, HtoE = (7.37)
^Ea

kmol of solute transferred/second

Kec
volume of packing x A C,

Example 7.8
In the extraction of acetic acid from an aqueous solution by benzene in a pilot plant scale
packed tower type extractor, following data were measured.
(i) Cross sectional area of tower = 0.0045 m2
(ii) Height of packing = 1.4 m
(iii) Concentration of acetic acid in feed = 0.69 kmol/m3
(iv) Concentration of acetic in final raffinate = 0.684 kmol/m3
(v) Flow rate of extract phase = 5.6 x 10"6 m3/s
(vi) Concentration of acetic acid in solvent = 0.004 kmol/m3
(vii) Concentration of acetic acid in final extract = 0.0115 kmol/m3
Determine HloE from above data.
Equilibrium relationship for this system12 is C*B = 0.0247 C^,

where Cjs, Cw = concentration of acid, kmol/m3

Solution:
Process Engineering Channel

Total acetic acid transferred to extract (benzene) phase

= qVE (Cgi- CH{)
= 5.6 x lO-6 (0.0115 - 0.004) = 4.2 x I0"8 kmol/s
Equilibrium relationship C''B = 0.0247 CVI,

where, CB = Concentration of acid in benzene phase, kmol/m3

Cw = Concentration of acid in water phase, kmol/m3
@ProcessEng

Equilibrium concentration of acetic acid in benzene phase at inlet and outlet,

Cg, = 0.0247 x 0.684 = 0.0169 kmol/m3

Cg2 = 0.0247 x 0.69 = 0.0171 kmol/m3

 360 Introduction to Process Engineering and Design

Driving force at bottom, AC, = C^, - = 0.0169 - 0.004 = 0.0129 kmol/m3

Driving force at top, AC2 = - Q2 = 0.0171 - 0.0115 = 0.0056 kmol/m3

Logarithmic mean driving force

AQ-ACj 0.0129-0.0056

AC, 0.0129 1
In In
AC2 0.0056 J

AC|m = 0.008 748 kmol/m3

Superficial velocity of extract phase

H.„, =
h
"' ' Overall mass transfer coefficient based on extract

HtoE = (7-37)
K
Ea

Volumetric
vuiumcuu; uuw
flow rate
laic ui
of caiiuci
extract 5.6 x 10 -6
j.oaio
vE — —
Cross sectional area 0.0045
3
1.244 x lO" m/s

kmol transferred
(Volume of packing x AC, m)

4.2 x 10_8 ,
KF = = 7.62 x lO"4 s"1
(1.4 x 0.0045 x 0.008 748)

1.244 x 10"3
HtoE = "T = 1
-6325 m
7.62 x lO"4

Example 7.9
For the extraction system described in Examples 7.4 and 7.5, design the packed tower
type extractor.
Solution:
Process Engineering Channel

Feed flow rate F = 1000 kg/h. It contains 80% DMF and 20% water. At steady state it is
contacted with final extract

El =B(i+'yl')

E{ = 3070.72 (1 + 0.0625) = 3262.64 kg/h

% = -^L-, = Q-Q625 = 0.0588

@ProcessEng

1+9Y 1 + 0.0625

1
Pf =
w, VV'2

Pi P2
 Design of Liquid-Liquid Extractor 361

I()()t)
Pdmf = 944.5 kg/m-, Pwater = kg/m3
1
Pf= 7 = 955.1 kg/m3
0.8 0.2
944.5 1000

1
—
PExtract
VV| W2

Pi PI
3
Pch2ci2 = 1336 kg/m

Pdmf = 944 kg/m3

PF = = 1304.2 kg/m3
0.0588 + (1-0.0588)
944.5 1336 s

F 1000
Qvf - = 1.047 m3/h
Pf 955.1

£, 3262.64
IVE
Pf 1304.2
Volumetric flow rate of extract phase is greater than volumetric flow rate of feed.
Hence, extract phase is continuous phase and feed is dispersed phase.
Tower Diameter:
Let type of packing: SS pall rings, size = 25 mm
ap = surface area of packing = 205 nr/m3
e = fraction of void volume = 0.94
To find the flooding velocities by Crawford - Wilke correlation, first the following func-
tion must be determined.
/ \ 0.2 / \
a
8c Pc p
/= (7.34)
<

e
Q-

\ Pc \ /
>

1/4 v 1/4
CJ(. = 2. A',- CT (7.35)
Process Engineering Channel

(7DMf = 35.2 dyn/cm

Molar mass of DMF, M = 73.09

Pch2ci2:
a1/4 = [P] (pL - pG) (Sudgen's equation)
3
pL, pG in mol/cm
@ProcessEng

= 40 + 55.2x2 = 150.4
(Table 3-343, of Ref. 3)
pi = 1336 kg/m3

pM 1 x 85 273
Pg = x = 3.474 kg/m
RT (273 + 25) 1x22.414
 Introduction to Process Engineering and Design

i(r
x -L x = 0.0157 mol/cm3
PL = 1336x 6
10 85

10 1
PG = 3.474 x x —— x — = 4.087 x 10"5 mol/cm3
1 I06 85
cti/4 = 150.4 (0.0157 - 4.087 x lO"5) = 2.355
o = 30.765 dyn/cm
Mole fraction of DMF in extract phase.

0.0588/73.09
x, = = 0.0677
0.0588 ^ O-0.0588 N
+
73.09 85

1/4 — 1/4 — v 1/4

(J -*■! ^DMF 4" ( ^ -^l )^CH2Cl2

a ' = 0.0677 x 35.2I/4 + (I - 0.0677) x 30.765174

ac = 31.05 dyn/cm = 0.031 N/m
Pt-
Wi W2

Pc Pi P2

Pdmf = 0-802 mPa ■ s, PcH2a2 = 0.6 mPa ■ s

_1_ 0.0588 + (1-0.0588)

P< 0.802 0.6
= 0.61 mPa • s = 0.61 x I0~3 kg / (m ■ s)
Ap = pc -pd= 1304.2 - 955.1 = 349.1 kg/m3
To use Fig. (7.20), all variables must be in US customary units.

1 1
ctc = 0.031 05 x x- = 2.128 x 10-3 Ibf/ft
4.448 222 3.28
gc = 4.18 x 108 lb • ft / (Ibf • h2)

1
Process Engineering Channel

pc= 1304.2 x = 81.42 lb/ft3

1.601846x10'

3 I
pc = 0.61 x 10 x = 1.4756 lb/(ft • h)
-4
4.133 789x10

1
Ap = 349.1 x = 21.7936 lb/ft3
@ProcessEng

16.01846

an = 205 m2/m3 = 205 x 0 3048

' = 62.484 ft2/ft3
p I
= 0.94
 Design of Liquid-Liquid Extractor

\0.2 , \l.5
a
c 8c a..
/= (7.34)
\ re J vAPy

\0.2 \ 1.5
2.128 x 10-3 x4.18xl08 1.4756 V (62.484^1
x = 235.66
81.42 21.7936 0.94 J

From Fig. (7.20),

(vcf +v
DF)2 =600

1/2 l/2 7 62.484x1.4756

()" = 600 x = 679.45
81.42
V C C
CF IVC IVE 2.502
= 2.39
DF C
IVD c
ivF 1.047

((2.39 vDF )I/2 + )2 =679.45

6.482 vDF = 679.45

vDF = 104.82 ft/h and vCF = 250.52 ft/h

^ 0.3048
1 ,
or vnF = 104.82 x x = nnnn
0.009 m/s
DF
3600 1
vCF = 0.0215 m/s
Let vD = 0.5 vDF = 0.0045 m/s,
vc = 0.010 75 m/s

7r„2 Qvc 2.502/3600 n n. -

—D- = = = 0.065 m"2
4 ' 0.01075
D, = 0.288 m
Let D, = 0.3 m = 300 mm
Packing height:
H - N,0r x HIoR
NtoR = 5.345
Suitable correlation for HloR is not available in open literature for the given system. It
Process Engineering Channel

must be determined by pilot plant study. Here HUlR is determined by the same equation
that is derived for acetic acid - water - MIBK system.
\ 0.648
' 0.010 75 x 0 648
HWR = 0.2347 = 0.2347
\VD 0.0045

H,oR = 0.41 m
@ProcessEng

// = 5.345x0.41 = 2.19 m
Let H = 2.5 m
Resulting data:
Type of packing: 25 mm SS Pall rings
Inside Diameter of tower = 300 mm
Height of packing section = 2.5 m
 Introduction to Process Engineering and Design

7.7 SUPERCRITICAL EXTRACTION (SCE) (REF. 13 TO 20)

In liquid-liquid extraction solvents like water, elhylene glycol, chloroform, hexane,

ethyl acetate, etc. are contacted with feed mixure to separate the desired product.
Desired product is transferred to liquid solvent. Then desired product is to be
separated from solvent. In short by liquid-liquid extraction from a given feed
solution one can make new solution (solvent + solute). If separation of new solution
is easier than the same of the given solution, then extraction is called useful extraction.
Separation of solute from solvent is normally done by distillation. It consumes
large amount of energy. Also it is difficult to get 100% pure solute; absolutely
free from solvent by distillation.
In supercritical extraction, supercritical fluid is used as a solvent. Uptil now it
has been discussed that the fluid can exist as liquid or gas. But in addition to that
a fluid can also exist as supercritical fluid.
Supercritical fluid is any fluid at a temperature higher than critical tempera-
ture and at a pressure higher than critical pressure.
In Fig. 7.22 and Fig. 7.23, phase diagrams of carbon dioxide and water are
given. Supercritical regions for both the compounds are shown in the figures.

Supercritical Region

Liquid Region

Solid Regio Critical Point

Mc ling 0.98oC, 73.77 bar)
•=
5 i-
10
Region

Triple Point
56.560C, 5.18 bar)
Process Engineering Channel

T?
c

Sublimation
@ProcessEng

-100 50
Temperature (/), °C

Fig. 7.22 Phase Diagram (p-t Diagram) of Carbon Dioxide

Based on Data Contained in Thermodynamic Properties of Carbon Dioxide, by: R. Span
and W. Wagner. J. Phys. Chem. Ref. Data, 25(6), p. 1509, 1996.
 Design of Liquid-Liquid Extractor

I04
„ ,
Supercritical
Region
103
uid Region
102 - -i^o^
Solid ritical Point
si
Region '374.150C,
10 -
rrrr.-j
»-Melting

U vaponz
Vapour on
/
r3 lO"1
-O

3
10-2
3
M Trip c Point
aj
3 0.010C. 0.006 ba
lO-

10
-c
Co
lO"3 -

6
10 su bum.
ma ioi

lO"7

lO"8
-100 100 20 )0 40C 500
0
Temperature (/), C

Fig. 7.23 Phase Diagram (p-t Diagram) of Water

Based on Data Contained in
1. Vacuum Technology, Its Foundations, Formulae & Tables, by Leybold AG, Germany,
1987.
Process Engineering Channel

2. 1980 SI JSME STEAM TABLES. Japan.

3. Publication No. NRISTIR 5078 of National Institute of Standards & Technology,
USA. 1998.

7.7.1 Properties of Supercritical Fluid Solvents (SCFS) (Ref. 13, 14)

(i) In supercritical state, density of fluid is just like liquid density and hence
@ProcessEng

solvent power for extraction is also equivalent to liquid solvents. In

supercritical region density of the fluid is sensitively changing with pressure.
Slight change in pressure creates the dramatic change in density.
(ii) Viscocities of SCFS are equivalent to viscocities of gases. Hence they con-
sume less power for transportation. Also they provide lesser resistance to
heat transfer and mass transfer.
 Introduction to Process Engineering and Design

(iii) Molecular diffusivities of SCFS are intermediate to liquids and gases.

Dl is in the order of C x 10"9 m2/s (DL = diffusivity of liquid).
Dg is in the order of C x 10-5 nr/s (Dc = diffusivity of gas).

7.7.1.1 Advantages and Disadvantages of SCF Solvents

Over Liquid Solvents

(a) Advantages
(i) SCF solvents are easily and completely separated from extracted products.
This means SCF solvents give the product, nearly 100% free from solvent.
(ii) Reduction in pressure or increase in temperature separates the SCFS from
extracted products. Hence they require lesser energy for separation.
Hence, with SCE, near 100% recovery of solvent from extracted product is
possible with low cost, compared to liquid-liquid extraction with liquid
solvents.
(iii) SCF solvent has very low viscosity and higher diffusivity compared to liq-
uid solvent. Hence, it provides lesser resistance to mass transfer and also it
provides lesser friction during transportation.
(iv) SCFS provides very high value of selectivity, compared to conventional
liquid solvents.
Selectivity,

mass of solute/mass of non solute component of extract phase

a=
mass of solute/mass of non solute component of raffinate

_ (C/A)extract
(C/A)raffinate

Extraction is possible only if a > 1. If a >> 1, implies lesser number of

theoretical stages are required for desired separation. Hence with SCF
solvents, lesser number of theoretical stages are required for desired
separation. Consequently they require lesser height of extractor as compared
to conventional liquid solvents.
(v) With common SCFS like CCE, solvent recovery is possible at room tem-
perature or at temperature close to the room temperature. While the same is
Process Engineering Channel

not possible with conventional liquid solvent.

(vi) Common SCFS like CO2 is easily available with relatively low price as
compared to conventional liquid solvent.
(vii) SCFS like CO2 (dry) is non corrosive and nontoxic in nature.
(b) Disadvantages
(i) It is found by experiments that supercritical fluids, provide poor value of
distribution coefficient for extraction as compared to conventional liquid
@ProcessEng

solvents.
Distribution coefficient,

mass fraction of solute in extract phase at equilibrium

m = (7.1)
mass fraction of solute in raffinate phase at equilibrium
 Design of Liquid-Liquid Extractor

Hence solvent/feed ratio, required with SCF solvents, is very much higher
than conventional liquid solvents.
(ii) Except the few solvents like CO2, for other solvent like hexane, ethylene
glycol, etc, it is very difficult to achieve the supercritical state of fluid due
to the practical limitations. Choice of solvent is narrow with SCFS.
(iii) Certain SCFS are flammable (like propane, butanes, etc.) and hence ad-
equate safety measures are required in design.
Properties of CCX, H2O and n-hexane in supercritical region are given in Ref.
21. Properties of ethane, propane and butanes in supercritical region can be found
in Ref. 22.

Table 7.4 List of Supercritical Solvents and Their Properties23

Fluid tc (0C) pc (bar) Remarks

Carbon dioxide, (CCb) 31.00 73.77 Most Favourable
Dinitrogen monoxide, (N-,0) 36.45 72.40 Not stable
Xenon, (Xe) 16.60 58.68 High price, poor availability
Ethane, (C2H6) 32.27 48.80 Inflammable
Ethylene, (C2H4) 9.19 50.39 Inflammable
Water, (H20) 374.15 221.20 High temperature and pressure
operation, corrosive, high
latent heat of vaporization
Propane (C^H8) 96.67 42.47 Inflammable
«-Butane (C^iq) 152.03 37.97 Inflammable
/-Butane (CjHiq) 135.00 36.48 Inflammable

Among all these solvents, CCC and propane are used in commercial plants.
Water is also an useful SCF but requires a very high pressure operation.
CO2 is the most preferred as SCE solvent. Reasons are:
(i) It has low critical temperature (tc = 31.0oC).
(ii) It has relatively low critical pressure (pc. = 73.77 bar).
(iii) It is nontoxic and non-corrosive in nature (when dry).
(iv) It is easily available at low cost. It is available as a byproduct from many
industries; such as fermentation of molasses, ammonia plant, etc. It is present
Process Engineering Channel

in substantial amount in atmosphere as green house gas.

7.7.1.2 Advantages and Disadvantages of SCE Over

Conventional Unit Operations

(a) Advantages
(i) It consumes lesser energy compared to liquid-liquid extraction and distil-
lation, combined together. Hence, it requires lesser operating cost as com-
@ProcessEng

pared to extraction and distillation. It requires only electricity as a utility to

drive a compressor and a positive displacement liquid pump. With CO2 or
N2O, it also requires chilled water or brine for condensation.
(ii) Compared to the liquid-liquid extraction it gives purer products, nearly
100% free from solvent or foreign impurities.
 368 Introduction to Process Engineering and Design

(iii) SCF provides very high value of selectivity as compared to conventional

liquid solvents. Hence supercritical extractor requires lesser number of theo-
retical stages and lesser height, compared to liquid-liquid extractor.
(iv) Compared to (atmospheric) distillation, supercritical extraction can be op-
erated at lesser temperature, closer to room temperature. Liquid-liquid ex-
traction requires higher temperature in solvent recovery step. This advan-
tage is beneficial particularly for heat sensitive products.
(v) Products obtained by biotechnology route is usually a dilute solution
(< 10%) in water. For the separation of desired product from water by dis-
tillation requires very high amount of energy and operating cost. While for
the same separation, SCFE consumes very less energy and has low operat-
ing cost.
Several examples of herbal and heat-sensitive products are given in Ref.
20 with the use of CO2 as SCF.
One research paper mentions that operating cost required to separate
ethanol from dilute solution by distillation is 5 times higher than the same
by SCFE while currently fixed cost of distillation unit is one half that of the
SCFE unit.
(b) Disadvantages
(i) It requires higher capital investment as this operation is carried out at high
pressure. Fixed cost of compressor is relatively higher than cost of other
equipments. Also the cost of the extractor is high. There are only a few
suppliers of the technology and equipments of the plant of SCFE at present.
Hence the specialization of technology further increases fixed cost of plant
at present.
(ii) It provides very low value of distribution coefficient hence large amount of
solvent is required for separation.
(iii) Limited experience with its use in pilot and commercial applications. How-
ever, now pilot studies with CCL as SCF are available at certain research
institutes with sufficient data for scale-up.
(iv) Limited knowledge of design data. Also thermodynamics of supercritical
system is not fully understood till date.
Process Engineering Channel

7.7.2 Flow Sheet of Batch Supercritical Extraction (Ref. 13, 14)

Figure (7.24) is the flow sheet of SC Extraction plant which is operated in batch
wise manner. Operational steps are as follows.
(i) In bath extraction, feed is initially charged before starting carbon dioxide
circulation.
(ii) In CO2 vessel, CO2 is in compressed gas form but p <pc and temperature is
equal to room temperature.
@ProcessEng

(iii) From CO2 vessel, compressed gas passes through chilled water condenser
or brine condenser where CO2 is liquefied.
(iv) Liquefied CO2 is pumped by metering pump (a positive displacement pump)
to high pressure. At the discharge of pump, CO2 is liquid with p > p(. and
t < tc.
 Design of Liquid-Liquid Extractor

Recycled CO2

Extract

teed

►<K LG
eater

co2
Vessel

Solute
HcatcrQj
Liquefied

-a
Liquid Raffinate
pump

Fig. 7.24 Flow Sheet of Batch SCE Plant

(v) Compressed liquefied CO2 which is in liquid state atp> pc. and at tempera-
ture less than tc is converted to SCF by increasing the temperature above
critical temperature.
(vi) Supercritical COo is contacted with feed which was initially charged in the
batch extractor.
(vii) From the top of the extractor, extract phase (SC CO2 + solute) is obtained.
It is heated to the temperature at which soluble solute is separated into
insoluble solid or liquid.
(viii) Then pressure is decreased and SC CO2 is compressed to gaseous CO2
with p < pc and at temperature which is close to tc.
Process Engineering Channel

(ix) CO2 is circulated till the desired degree of extraction is obtained. A level
indicator can be provided on the separator.
(x) Once desired degree of extraction is obtained, system is depressurized.
Raffinate phase is separated from the extractor at atmospheric pressure.
New feed then can be charged to the extractor.
@ProcessEng

7.7.3 Application of SCE (Ref. 13 to 20)

SCE finds its application in food, pharmaceutical, petroleum refineries, solid

fuel industries and polymer industries. Extensive research work is going on other
areas of applications.
A. Commercial applications
(a) In decaffenation of coffee
 Introduction to Process Engineering and Design

(b) In deasphalting of oil

(c) In extraction of essence from fragrant materials
(d) In the separation of aromas and oils from spices
(e) In spray painting and coating
(f) In chromatographic analysis of polymer
(g) Supercritical fluid polymerization
(h) In extraction of herbs
(i) In purification of active pharmaceutical intermediates (API)
(j) In isolation of eico sapentanoic acid (EPA) from fish oils
(k) Purification of a vitamin intermediate
(1) Purification of a reactive multifunctional acrylic monomer
(m) Extraction of cholesterol from butter
(n) Extraction of oligomers from high vacuum sealants.
(0) Extraction of sterols from deodorized distillate of edible/non-edible oils.
B. Applications under Research and Development
(a) Extraction of various chemicals from coal and wood
(b) Extraction of organic chemicals from its dilute solution in water. (This ap-
plication is useful in biotechnology route and also in the recovery of chemi-
cals from wastewater stream)
(c) In separation of liquid hydrocarbon mixtures which are difficult to separate
by convertional techniques
(d) Separation of arometics from waste solid material such as tobacco dust
(e) In regeneration of adsorbent materials
(f) Extraction of oil from oil - containing conventional and unconventional
seeds, e.g. soybeans, jojoba beans, corriander, etc.
(g) In deodorization of vegetable and animal oils.
(h) In extraction of oil from potato chips
(1) In recovery of citrous oil from peelings
(j) Extraction of anlicancer drugs and other substances from plants (herbs)
(k) In refining of pyrethrum to obtain pyrelhrin insectisides
(1) Destruction in hazardous waste and production of biocrude from organic
waste (water is used as SC fluid)
(m) In extraction of chemicals from used automotive tires
(n) In separation of monoglycerides from the mixture of glycerides
Process Engineering Channel

(o) In paper deacidification and preservation

(p) In plastic recycling
(q) In textile dyeing
Many other applications are under R&D and can be found from literature.

7.7.4 Use of Cosolvents and Surfactants (Ref. 15)

One of the major limitations of SCE is availability of very few suitable solvent.
@ProcessEng

Most suitable solvent is supercritical CO2 which is nonpolar in nature.

Many nonvolatile polar substances cannot be dissolved easily in nonpolar SC
CO2. Most of the organic compounds are polar in nature, e.g. ethanol, ethylene
glycol, etc.
Polar solvents have high critical temperature. Hence they involve very high
cost in extraction. Also other problems like thermal cracking may take place of
 Design of Liquid-Liquid Extractor

such solvent as SC solvent results in its rejection. It is found by experiment that

an addition of small amount of polar liquid solvent (1 to 10 mole %) in SC CO2,
dramatic impovement in the solubility can be achieved.
Take for example case of hydroquinone which dissolves very little in pure SC
CO2. Addition of 2.8 mole % methanol increases hydroquinone's solubility by a
factor of 6. Addition of 2 mole % tributyl phosphate (TBP) increases
hydroquinone's solubility by a factor of 250.
Hence TBP is much more effective than methanol as cosolvent. Selection of
the correct cosolvent requires detailed knowledge of chemistry and molecular
structure of polar and non-polar compounds. Hence, selection of right cosolvent
is very important.

7.7.5 Few Commercial Applications

It will be interesting to study two case studies of supercritical extraction/process-

ing.

7.7.5. / Decaffeination of Coffee (Ref. 17)

Coffee industry is an important food grade industry. With industrialization and

increasing demand of refreshers, there has been an increase in consumption of
coffee in most of the parts of world. Coffee seeds contain 1-3% caffeine. Taking
large dosages of caffeine produce adverse effect on human body, but at moderate
level no major harmful effects are observed.
Pure caffeine is a white powder, soluble in water and various organic solvents.
Hot water is an excellent solvent for decaffeination. There are many plants in the
world which extract caffeine from raw coffee. One of them is coffee decaffeination
plant in Houston, USA, built by Kraft General Foods Ltd. The process, used by
Kraft, is shown in Fig. (7.25).

Process Description The moist green coffee beans are charged to an extrac-
tion vessel having 7 ft (2.13 m) diameter and 70 ft (21.33 m) height. Carbon
dioxide is charged from the bottom of extractor in supercrifical state. From
supercritical extract, caffeine is then recovered by counter current water wash,
carried out at the same pressure.
Process Engineering Channel

CO2 Green moist coffee

Vessel Caffeine Lean CO?

Make - up E
X 111 - Fresh water
T JlT
R Concentrated
A Wash
. Caffeine Solution
@ProcessEng

C Tower
T Reverse
O *- A A A Osmosis Unit
Reeireulator

| Liquid
Decaffeinated Pump
green coffee
Fig. 7.25 Decaffeination Process
 Introduction to Process Engineering and Design

The depleted carbon dioxide is recycled to the extractor. Caffeine rich aque-
ous stream is concentrated by reverse osmosis.
The Lipton tea decaffeination process is similar to Kraft process (Lipton tea
decaffeination plant is in Germany.) except that the caffeine is removed from the
carbon dioxide by passing the solution through a bed of activated carbon.
The caffeine recovery from the extract is the key part of the process. As the
decaffeinated green coffee is finally contacted with solvent, equilibrium distribu-
tion of caffeine between beans and solvent decide the percentage of unrecovered
caffeine in the beans.
If caffeine concentration in the solvent (SC CO2) is reduced to 0.002 mass %
in recovery step, then it gives equilibrium concentration of caffeine remaining in
the processed beans to about 0.16 mass%.
Hence, it is very much necessary to remove caffeine from extract phase as
much as possible. One way is to reduce the pressure of SC extract to atmospheric
pressure, but it is not an economical option.
It is suggested not to try to reduce the concentration of caffeine from coffee
below 0.16% as it is not economical. Hence the selection of recovery process and
maximum extraction of caffeine is very important.

7.7.5.2 ROSE Process (Deasphalting of Oil) (Ref. 24)

Solvent extraction has been used to separate valuable components from heavy oil
and residuals from less desirable material. One of them is propane deasphalting.
In the refinery, bottom product of vacuum distillation column is known as re-
siduum. Propane deasphalting is used to separate the residuum into three frac-
tions; (i) lube oil (ii) resin and (iii) asphalt. It uses liquid propane as solvent to
extract lube oil and resin from residuum and to reject high molar mass asphalt, as
reffinate. Solvent recovery in conventional propane deasphalting consists of se-
ries of flash vessels and steam stripping. Entire propane is recovered as vapour at
lower pressure. It is converted into high pressure liquid propane by compression
and liquefaction and recycled back to extractor. Thus, energy consumption in
conventional propane deasphalting is very high and it demands the use of new
technique. The ROSE (Residuum Oil Supercritical Extraction) process is a new
process developed by Kerr-McGee's R&D group. ROSE process produces iden-
Process Engineering Channel

tical products from residuum (lube oil, resin and asphalt) but it consumes less
energy.
Details of three products obtained from residuum are as follows:
(i) Asphalt: It is the heaviest, most viscous and the most hydrogen deficient
fraction of crude petroleum oil. At room temperature it is a dark brown to
black friable solid. Its ring and ball softening point ranges from 70° to 200oC.
Carbon to hydrogen ratio is 9 to 11.6 by mass. It is extremely difficult to
@ProcessEng

remove sulphur, nitrogen or metals from asphalt. Hydrotreating and crack-

ing catalysts are rapidly coked, deactivated and poisoned by asphalt.
(ii) Resin: It is an intermediate fraction, lighter than asphalt and heavier than
deasphalted oil or lube oil. Resin can be hydrotreated, hydrocracked, ther-
mally-cracked or even coked to produce more volatile products. Resins are
less viscous, lower in metals, sulphur and carbon. Resins have less C/H
ratio than asphaltene.
 Design of Liquid-Liquid Extractor

■—
o
o- ra
3
Q.
t- u
o oo
p. c o
■si
« ?3
■o J=
— .ra --
d> O ^
h- CO p h
= h
C- 5
Q.
c
cc •— ■—
4= O
-4—» _aj
Q. CJ C3 2 -x
o o jc
5 3 X O o U OJ
o- m E U Q Qi H
i:
f-c-WSUQctic^

si

O
< <

1
si t/1
oo
=: (U
u
o

> UJ
oo
ci o
s_ Qi
-
Q si o
(N
P
DO

si
>
si
p-
Q

H -=
ss
> <
Process Engineering Channel

si
s-

C
CO 2 y

o US
Si
@ProcessEng

s
3
u 3
O .3
Si
 Introduction to Process Engineering and Design

(iii) DAO or Lube Oil: Deasphated oil or lube oil is a clean product containing
substantially lower metals and carbon residue than either asphalt or resin.
DAO can be sent for hydrotreating, hydrocracking or catalytic cracking,
without any further purification.

7.7.5.3 Process Description

The residuum is charged to extractor where it is contacted with liquid propane at

elevated pressure. In ROSE process also, extraction is liquid-liquid extraction,
similar to conventional propane deasphalting. It is not the supercritical extrac-
tion. As an extractor, either Mixer-settler or Rotating Disc Contractor (RDC) is
used. From the extractor, asphalt is obtained as raffinate phase, but it is contami-
nated by very less amount of propane. Propane vapour is separated from raffinate
phase by flashing and stripping in tower T] which is a flash vessel cum stripper.
Extract phase, containing large amount of liquid propane, resin and lube oil, is
passed through heater El where it is heated to the temperature at which resin
becomes insoluble and is separated from the extract phase. Propane rich layer
and resin layer are separated in decanter Z),. Traces of propane from resin layer is
separated by flashing and stripping in the tower T2.
The remaining propane-oil solution is heated to higher temperature by two
heaters E2 and H2 in series. At this temperature liquid propane is converted into
supercritical propane. DAO or lube oil is not soluble in supercritical propane,
hence it is separated from propane in decanter D2. Traces of propane from DAO
or lube oil is separated by flashing and stripping in tower T3. Supercritical pro-
pane from D2 is passed through heat exchanges E2 and where its sensible heat
is utilized for heating. Then in heat exchanger C2 it is liquefied. Liquified pro-
pane is recycled back to extractor by pump Pv Difference between discharge
pressure and suction pressure of pump Px is relatively low. Pump Px develops
only differential pressure necessary to overcome system pressure drop.
Small amount of propane vapour, stripped off from the towers TX,T2 and 7^, is
condensed in condenser C,. Condensate is sent to tank 5|. This intermediate
hold-up tank is maintained at lower temperature and at lower pressure, where
make up liquefied propane is also added. Small amount of propane from this tank
(7 to 15% of the total required in extractors) is pumped by pump P2 and sent to
Process Engineering Channel

suction line of pump Px. Pressure difference around pump P2 is quite higher than
the same around pump Px.
Thus in ROSE process, extraction is carried out in subcritical region or as
liquid-liquid extraction. Only properties of supercritical fluid are utilized in sol-
vent recovery step.
Advantages of Rose process over conventional propane deasphalting are as
follows.
@ProcessEng

(i) 85 to 93% of the extraction solvent is recovered as supercritical fluid in the

oil separator without evaporation and pressure reduction. Also, the concept
of energy integration is applied in two heat exchangers. (E, and E^ to save
the utilities. Hence energy required by ROSE process is substatially lower
than the same required for conventional propane deasphalting.
 Design of Liquid-Liquid Extractor

(ii) ROSE process requires less maintenance cost.

(iii) Increase in propane to feed ratio improves the quality of products. With
ROSE process, higher solvent to feed ratio is affordable, hence it results in
better quality of products.
ROSE process is competitive, well established and commercially proven tech-
nology. It is licensed by more than 15 companies worldwide.

7.7.5.4 Conclusion

In the early stages of development of the Supercritical Fluid Extraction, the re-
quirement of expensive equipments, lack of proper and appropriate techniques
were the main hurdles of adoption and commercialization of the technology.
But now in the changed scenario of improvement in the SCE techniques, in-
creasing cost of energy and increasing cost of conventional solvents makes this
unit operation more feasible and attractive. Still there is a large scope for the
development of supercritical extraction technology. More research work is re-
quired to improve the distribution coefficient of SCE system. In future, it is cer-
tain that this unit operation will be applied in many processes.

Exercises

7.1 A feed stream having flow rate of 1000 kg/h and containing 40 mass % styrene and
60 mass % ethyl benzene is to be extracted with ethylene glycol as solvent. Extrac-
tion is to be carried out in multistage counter current extractor. Final raffinate is to
be extracted down to 1 percent styrene. Determine (a) minimum amount of solvent
required for the desired separation and (b) number of theoretical stages required for
desired separation if the actual amount of solvent is 5000 kg/h.

Table 7.5 Liquid-liquid Equilibrium Data3 of Ethyl Benzene-Styrene-

Ethylene Glycol at 25°C

Mass % in raffinate Mass % in extract

Ethyl benzene Styrene Ethylene glycol Ethyl benzene Styrene Ethylene glycol
90.56 8.63 0.81 9.85 1.64 88.51
80.4 18.67 0.93 9.31 3.49 87.2
Process Engineering Channel

70.49 28.51 1.00 8.72 5.48 85.8

60.93 37.98 1.09 8.07 7.45 84.48
53.55 45.25 1.2 7.35 9.25 83.4
52.96 45.84 1.2 7.31 9.49 83.2
43.29 55.32 1.39 6.3 12.00 81.7
41.51 57.09 1.4 6.06 12.54 81.4
(From Table 15.2 of Ref. 3)
@ProcessEng

7.2 For the extraction described in Exercise 7.1, if packed tower is used as extractor
then (i) find the value of NloR for S = 5000 kg/h and (ii) determine the tower diameter.
7.3 A feed mixture containing 60 mass % methyl cyclohexane and 40 mass % n-heptane
is contacted with pure aniline as solvent. Extraction is carried out in counter current
manner in four mixer-settler vessels. Stage efficiency of mixer-settler may be
assumed equal to 1. Solvent to feed ratio (mass basis) is kept 4. Feed flow rate is
200 kg/h. Find the resultant product flow rates and product compositions.
 376 Introduction to Process Engineering and Design

Table 7.6 Equilibrium Data

Hydrocarbon phase, mass % Aniline rich phase, mass %

Methyl cyclohexane n-Heptane Methyl cyclohexane n-Heptane
0.0 92.6 0.0 6.2
9.2 83.1 0.8 6.0
18.6 73.4 2.7 5.3
22.0 69.8 3.0 5.1
33.8 57.6 4.6 4.5
40.9 50.4 6.0 4.0
46.0 45.0 7.4 3.6
59.0 30.7 9.2 2.8
67.2 22.8 11.3 2.1
71.6 18.2 12.7 1.6
73.6 16.0 13.1 1.4
83.3 5.4 15.6 0.6
88.1 0.0 16.9 0.0

(Ref. : 7, p. 325)
(Hint: Assume /j-heptane and aniline as completely immiscible liquids to simplify the
calculations.)

7.4 Design a mixer settler for Exercise 7.3.

Residence time required in mixer to achieve equilibrium = 8 min
Type of agitator of mixer = 45° pitched blade turbine
Tip velocity of agitator = 200 m/min
7.5 A feed mixture containing 20 mass % acetic acid and 80 mass % water is contacted
with nearly pure butyl acetate as solvent to recover acetic acid. Extraction is carried
out in packed tower. Feed flow rate is 1000 kg/h. Final raffinate leaving the packed
tower should contain less than or equal to 1% (by mass) acetic acid. Determine the
following:
(i) Minimum amount of solvent required for desired separation.
(ii) Value of A'toR for actual amount of solvent 5 = 2 Sm.
(iii) Tower diameter required for packed tower.
(iv) Determine the height of packing. Assuming that Eq. (7.33) is valid for acetic
acid-water-butyl acetate system for finding //t(lR.
Process Engineering Channel

Data:

Table 7.7 Liquid-Liquid Equilibrium Data (mass %) at 2S°C.

Solvent rich layer Water rich layer

Water Butyl acetate Acetic acid Water Butyl acetate Acetic acid

1.8 94.8 3.4 90.5 0.8 8.7

@ProcessEng

3.7 84.6 11.5 78.9 1.1 20.0

4.7 82.0 13.3 75.6 1.2 23.2
7.8 73.0 19.2 68.0 1.6 30.4
oc

68.0 23.1 65.0 2.3 32.7

14.7 56.0 29.3 56.3 5.6 38.1
 Design of Liquid-Liquid Extractor

References

1. Treybal R. E. Liquid Extraction, McGraw-Hill Book Company, Inc., USA, 1951.

2. Rawat B. S. Aromatic Extraction, Indian Institute of Petroleum, Dehradun, 2000.
3. Perry R. H. and Green D. Perry's Chemical Engineers' Handbook, 6th Ed., McGraw-
Hill Book Company, USA, 1984.
4. Treybal R. E. Mass Transfer Operations, 3rd Ed., McGraw-Hill Book Company,
USA, 1980.
5. DMF Recovery and Purification, Technical Catalogue of Dupont Co., USA.
6. Nanoti. S. M., Industrial Extraction Equipment Selection and Process Design, In-
dian Institute of Petroleum, Dehradun, 2000.
7. Brown G. G., Unit Operations, John Wiley and Sons, Inc., New York, 1950.
8. Schweitzer, Handbook of Separation Techniques for Chemical Engineers, McGraw-
Hill Book Company, USA, 1979.
9. McKetta. J. J., Encyclopedia of Chemical Processing and Design, Vol. 21, Marcel
Dekker Inc., USA, 1984.
10. Nagata, S.. Mixing, Kodansha Ltd., Japan, 1975.
11. Coulson, J. M. and Richardson, J. P., Chemical Engineering, Volume 2, Pergamon
Press, New York, USA, 1987.
12. Backhurst, J. R. and Harker J. H., Chemical Engineering, Volume 5, Pergamon
Press, New York, USA, 1989.
13. Awasthi, A., Trivedi, R. A., Chem. Engg. World, Vol. XXXII, No. 10 Oct. 97,
p. 65.
14. Bork, M., Chem. Engg. World, Vol. XXXII.
15. Chrastil, J., J. Phys. Chem., 86 1982, p. 3012
16. De Hann, A. B, De Graauw, J., Ind. Eng. Chem. Res., 30 1991, p. 2463.
17. Kohn P. M. and Savage P. R., Chem. Engg.. 86 (6), March 12, 1979, p. 41.
18. Laheire, R. J.. Fair J. R., Ind. Engg. Chem. Res., 26, 1987, p. 2086.
19. Moore S. and Samdini S. Chem. Engg., 32, March 1994.
20. Mukhopadhyay, M. Natural Extracts using Supercritical Carbon Dioxide, CRC
Press LLC, USA, 2000.
21. Bhatt, B. L, Design Databook, Properties of Steam, Selected Refrigerants, Hexane
and Brines, CBS Publishers and Distributors, New Delhi, 2007.
22. Younglove, B. A. and J. F. Ely, J. Phy. Chem. Ref. Data, 16(4), 1987, p. 577.
23. Bhatt, B. I. and S. M. Vora, Stoichiometry, 4lh Ed., Tata McGraw-Hill Publishing
Process Engineering Channel

Co. Ltd.. 2004.

24. Nelson, R. R., Chem. Engg. World, 24(7), 1989, p. 47.
@ProcessEng
 n
Chapter
o

Process Design of

Distillation Columns

8.1 INTRODUCTION

In simple terms, vaporization followed by condensation is known as distillation.

It is a method of separating components of solution which are relatively volatile.
Distillation is the most widely used separation method in chemical industries.
Simple distillation or batch distillation was known in first century. Multistage
counter current distillation was invented in 1830 by Aeneas Coffey of Dublin1.
He used tray lower for separating 95.6% ethanol (by mass) from its dilute solu-
tion in water. But as of today 100% reliable method for designing of distillation
column, which can be applied to all systems without any limitation, is not avail-
able. All methods have limitations. Hence process design engineers use more
than one method for the design of distillation column. For an entirely a new
mixture, it is better to verify the design of its distillation column first on the pilot
plant scale column before applying it at commercial or large scale.

8.2 CRITERIA OF SELECTION

For a given mixture, if all the components are relatively volatile and are required
to be separated in pure form, then distillation is the first choice.
If the relative volatility of the two adjacent components is very high, then
evaporation is preferred. For example, concentration of orange juice.
Process Engineering Channel

If relative volatility of two adjacent components is very low: close to I (e.g. 10

to 30%, by mass acetic acid in water) or equal to 1 (e.g. azeotropic mixture,
95.6% by ethanol in water), special type of distillation like Azeotropic Distillation
or Extractive Distillation is used. For the same case, liquid-liquid extraction,
membrane separation or crystallization may be more economical. Examples: (a)
For the separation of pure acetic acid from 10% (by mass) aqueous acetic acid
@ProcessEng

solution, liquid-liquid extraction using ethyl acetate as solvent is more economical

than azeotropic distillation of the same solution using butyl acetate or ethyl acetate
as an entrainer. (b) For the separation of pure ethanol from its azeotropic mixture
with water. [95.6% ethanol (by mass) in ethanol - water solution], pervapouration
unit consumes less than 20% of the energy, than that used in azeotropic distillation.
Also for the same separation, pervapouration unit requires low pressure steam
 Process Design of Distillation Columns 379 |

(to maintain 80oC temperature) which can be obtained by flashing the condensate
of high pressure steam, (c) For the separation of /?-xylene from the mixed xylenes,
crystallization is used.
If the separation of only one component is required rather than a separation of
all the components of the mixture, then absorption, stripping or liquid-liquid
extraction may be more economical than distillation.
Examples:
(a) For the separation of penicilin from the complex mixture, liquid-liquid
extraction is used.
(b) For the removal of hydrogen and methane from aromatics, stripping is used.
(c) For the removal of propane from the mixture called asphalt, stripping is
used. Volatility of propane is very high compared to volatilities of other
components of the asphalt.
(d) For the removal of hydrogen sulphide from the natural gas mixture, absorp-
tion using ethanolamines as solvent is used.
(e) For removal of ammonia from lean aqueous solution, steam stripping is
preferred.
(f) If all components of air are to be separated in pure form (nitrogen, oxygen,
argon, etc.) cryogenic distillation is preferred. But if only nitrogen in pure
form is to be separated from air then pressure swing adsorption (PSA) is
preferred.

8.3 SELECTION OF EQUIPMENT FOR DISTILLATION1 2

In most of the cases, distillation is carried out either in a tray tower or in a packed
tower. Criteria of selection between tray tower and packed tower are as follows.
(a) For high vacuum distillation, a packed tower is selected. Packed tower
generally provides lower pressure drop as compared to the tray tower. For
example in the distillation of the mixture of monochloroacetic acid and
acetic acid, absolute operating pressure in the reboiler should be less than
50 torr a to avoid thermal cracking of bottom product (monochloroacetic
acid). For this case, packed tower should be selected. Packed tower provides
lower residence time for liquid as compared to tray tower. The rate of thermal
cracking is directly proportional to residence time. For highly heat sensitive
product, decrease in boiling point means improvement in the quality. The
Process Engineering Channel

rate of thermal cracking increases exponentially with the temperature. For

very high vacuum distillation, short path distillation is used. Example:
Separation of vitamin E from its crude mixture (such as soybean oil
deodorizer distillate) is carried out in short path distillation equipment.
Operating absolute pressure in short path distillation can be as low as
0.05 mbar or 50 pbar a.
(b) For very small tower diameter packed tower is preferred. With large tower
@ProcessEng

diameter, tray tower is preferred. With very small diameter (less than 150
mm), fabrication of trays is difficult while with large diameter, liquid distri-
bution is difficult in the packed tower.
(c) For handling higher ratio of liquid flow rate to vapour flow rate, packed
towers are preferred. For very law liquid flow rate, tray tower is selected.
But for very low L/V ratio, tray tower is selected. Packed tower requires
minimum wetting rate to work efficiently.
 Introduction to Process Engineering and Design

(d) For corrosive system, packed tower with plastic packings like polypropylene
packings, glass fibre reinforced plastic packings, etc. is more economical
than tray tower made from special metal alloys. Example: For the separa-
tion of methyl iodide and acetic acid, packed tower with glass fibre rein-
forced plastic packings is more economical than tray tower which should
be entirely made from Hastalloy-B.
(e) If the side products are to be drawn from the distillation column, like the
distillation columns of refinery, tray tower is preferred.

8.4 DISTILLATION COLUMN DESIGN

The design of a distillation column can be divided into the following steps.
(a) If the feed mixture contains more than two components, then select two key
components from all the components of feed mixture.
(b) Decide the operating pressure of distillation column. At the operating pres-
sure, find the vapour-liquid equilibrium data.
(c) Specify the degree of separation required. In case of a binary distillation,
decide the top (distillate) and the bottom (residuce) product compositions.
In case of multicomponent distillation, decide the distribution of key com-
ponents in distillate and residue. Also, find the distribution of non key com-
ponents in the same. Complete the material balance.
(d) Determine the minimum reflux ratio Rm.
(e) Determine the optimum reflux ratio R and find the number of theoretical or
equilibrium stages required for the desired separation.
(f) Select the type of tower: tray lower or packed tower (as discussed in
Sec. 8.3). Select the type of tray in tray tower or type of packing in packed
tower.
(g) Find tower diameter and pressure drop across the tower. Decide the top
disengagement and bottom disengagement spaces.
(h) Determine the tray efficiency and find the actual number of trays in case of
tray tower or find F1ETP (height equivalent to theoretical plate) and decide
the height of packing in packed tower. In case of packed tower, design the
liquid distributor, redistributor, packing support, etc.
(i) Select the material of construction for all parts. Design the suitable insula-
Process Engineering Channel

tion system.
(j) Design the condenser and reboiler.
(k) Decide the control methodology for the distillation column, line sizes and
locations of all nozzles.
(1) Mechanical design of distillation column which also includes design of
skirt support for the distillation column.
@ProcessEng

Calculation and equations for the first five steps are different for binary and
multicomponent distillation. In this chapter first eight steps are discussed in detail.

8.4.1 Step I: Selection of Key Components1,2

If the feed mixture to distillation column contains only two components, then it is
called binary distillation. In many cases feed mixture actually contains more than
 Process Design of Distillation Columns

two components, but it is considered as binary mixture because the amounts of

other components (except two key components) are negligible. Step 1 is not valid
for binary mixture or binary distillation.
When a feed mixture to distillation column contains more than two compo-
nents, it is called multicomponent distillation. In such a distillation, it is not pos-
sible to obtain more than one pure component in single column. For the separa-
tion of N' component mixture by distillation, if all the components are to be
separated in pure form, then at least N'-\ distillation columns are required.
In multicomponent distillation, one cannot specify the complete composition
of the top and bottom products independently. For example: A feed mixture to
distillation column is 100 kmol/h containing 20 kmol/h ethane, 30 kmol/h pro-
pane and 50 kmol/h of butane.
One cannot fix distillate composition: 20 kmol/h ethane, 29 kmol/h propane, 1
kmol/h butane and Residue composition: 1 kmol/h propane, 49 kmol/h of butane.
One can fix that distillate will contain 29 kmol/h of propane and 1 kmol/h of
butane, and residue will contain 1 kmol/h of propane and 49 kmol/h of butane.
Thus one can fix only distribution of two components of feed mixture in distil-
late and residue but not the distribution of all components . Before starting the
design of multicomponent distillation, two key components are selected. Key
components are the two components of the feed mixture between which one
likes to make the sharp separation. Two key components are further divided as
light key component and heavy key component. More volatile key component is
called light key and less volatile component is called heavy key.
Light key component: It is a component of the feed mixture which is desired to
be kept out of the bottom product. It is the component of feed which is present in
residue in important amount, while components lighter than light key are either
not present or present in very small amount. If all components of feed are present
in residue with sufficient concentrations, then most volatile component of resi-
due is the light key component.
Heavy key component: It is a component of feed mixture which is desired to be
kept out of the top product. It is the component of feed which is present in distil-
Process Engineering Channel

late in important amount, while all components heavier than the heavy key are
not present or present in negligible amount. If all components of feed are found
in distillate with sufficient concentrations, then the least volatile is the heavy key
component.
If the light key and heavy key components are selected as per the order of
volatility then they are known as adjacent keys. If any other component lies in
between them, then they are known as split keys.
@ProcessEng

Components of the feed mixture other than key components are known as
non-key components. The non key components which are distributed in top and
bottom products are known as distributed components. Any component which
does not appear in either top or bottom product up to significant extent is known
as non distributed component.
 Introduction to Process Engineering and Design

8.4.2 Step 2: Selection of Operating Pressure and Determination

of Vapour-Liquid Equilibrium Data

8.4.2.1 Selection of Operating Pressure

In many cases operating pressure in distillation column is fixed by the tempera-

ture of the cheapest cooling medium (cooling water), which must be able to con-
dense the distillate vapour. For this, bubble point of distillate (in case of total
condenser) should be sufficiently greater than cooling water temperature. In case
of partial condenser, bubble point of reflux (is equal to dew point of distillate
vapour) should be sufficiently greater than temperature of cooling water. But if,
this operating pressure (based on cooling water temperature) is calculated to be
very high, then chilled water or brine can be considered as cooling medium for
the overhead condenser. Operating pressure in distillation column is always less
than the critical pressure of top product or temperature of cooling medium of
overhead condenser cannot be greater than critical temperature of top product. In
many cases, distillation is carried out under vacuum to avoid the thermal degra-
dation of heat sensitive product or to facilitate the use of cheaper heating medium
like saturated steam in reboiler or to alter the vapour-liquid equilibrium data.
Examples for the Selection of Operating Pressure:
(i) Distillation of acetaldehyde-ethanol-water mixture is carried out at about 3
atm g pressure. Pure acetaldehyde is the top product. Normal boiling point
(tB) of acetaldehyde is 20.2oC. To facilitate the use of cooling water as a
cooling medium in the overhead condenser, boiling temperature or conden-
sation temperature of acetaldehyde should be sufficiently greater than the
design temperature of cooling water from cooling tower (say 320C). Also
the product acetaldehyde is stored in bullet type storage tanks which are
exposed to atmosphere. Hence, to reduce the cost of storage or to avoid the
use of insulation around storage tank and to avoid the use of any refrigera-
tion system for the storage tank, boiling point of acetaldehyde should be
sufficiently greater than atmospheric temperature (50oC-maximum). Con-
sidering all these aspects, condensation temperature (is also equal to boil-
ing temperature of pure component) of acetaldehyde is fixed at around 60oC.
For getting 60oC as a condensation temperature of acetaldehyde, required
Process Engineering Channel

operating pressure at the top of distillation column is around 3.6 atm g

(vapour pressure of acetaldehyde at 60oC).
(ii) For the separation of methyl chloride from the mixture of chloromethanes,
normal boiling point or condensation temperature of pure methyl chloride
is -240C. At 10 atm a pressure, its condensation temperature is 47.30C.
Hence to facilitate the use of cooling water as a cooling medium in over-
head condenser, this distillation column can be operated at 10 atm a pres-
@ProcessEng

sure. Similarly in case of distillation of ammonia (Example 8.7), saturation

pressure of ammonia at 40oC is 1555.5 kPa a. Hence, the column is oper-
ated at about 15 bar g to facilitate condensation of ammonia at 40oC in the
condenser with cooling water at 320C.
 Process Design of Distillation Columns

(iii) For the separation of ethane from the mixture of ethane, propane and butanes
by distillation, cooling water cannot be used as a cooling medium in the
overhead condenser because critical temperature of ethane (tc = 32.30C) is
not sufficiently greater than the temperature of cooling water (say 320C).
Minimum driving force required for heat transfer in shell and tube type
overhead condenser is 3 to 50C. At 10oC, vapour pressure of ethane is 30
atm a, hence chilled water (at 5.70C) can be used as a cooling medium in
the overhead condenser, but the required operating pressure is 30 atm a,
which is high particularly for larger diameter column. At 20 atm pressure,
condensation temperature of pure ethane is - 6.40C, hence suitable brine
system can be used as a cooling medium in the overhead condenser, but it
will require higher cost of refrigeration and insulation. In the plant, if this
column is following to demethanizer column, then top product stream of
demethanizer can be used as a cooling medium in the overhead condenser
of deethanizer column and operating pressure can be reduced to very low
value, close to atmospheric. Optimum solution should therefore be worked
out.
Vacuum Distillation: For heat sensitive material or to facilitate the use of cheaper
heating medium in reboiler or to alter the vapour-liquid equilibrium data, distil-
lation column is operated under vacuum. Advantages and disadvantages of vacuum
distillation are:
Advantages:
(a) It prevents thermal decomposition of heat sensitive material. Example: In
separation of monochloroacetic acid and acetic acid by distillation, mono-
chloroacetic acid is obtained as bottom product. Boiling point of monochloro-
acetic acid must be restricted below 120oC, otherwise thermal degradation
can take place. If the boiling point of monochloroacetic acid is kept at
109oC, then operating pressure at bottom of column must be equal to 40
torr (absolute).
(b) It allows the use of more economical heating medium such as saturated
steam against hot oil in high capacity plant. Example: For the separation of
ethylene glycol-water mixture by distillation, ethylene glycol is obtained
as bottom product. Its normal boiling point is 1970C. Use of saturated steam
Process Engineering Channel

as a heating medium could be economical up to 180oC. Hence, this column

is better to be operated under vacuum to facilitate the use of saturated steam
against the use of hot oil.
(c) It requires fewer stages or lower reflux ratio or both in many cases where
relative volatility increases with decrease in the operating pressure.
(d) In some case vacuum breaks the azeotrope and make the separation easier.
@ProcessEng

Example: If the distillation of ethanol water mixture is earned out below 70

torr absolute pressure, azeotrope does not form.
(e) It reduces undesirable side reactions, if they are taking place. Example:
Distillation of ethyl benzene-styrene mixture under vacuum reduces
polymerization.
(f) Vacuum distillation provides safety in the distillation of toxic or hazardous
material. Example: For the separation of nearly 100% pure nitric acid from
 Introduction to Process Engineering and Design

the azeotropic mixture of nitric acid and water, extractive distillation is

used. This extractive distillation uses concentrated sulphuric acid as sol-
vent. Material of construction of this column is borosililate or high quality
glass. This column is operated under slight vacuum for safety purpose. Here,
vacuum also facilitates the use of saturated steam in reboiler.
(g) It increases product recovery when dealing with maximum temperature con-
straints. Example: Refinery vacuum tower.
Disadvantages of Vacuum Distillation:
(a) It requires larger column diameter and larger diameter vapour line.
(b) Because of the reduction in condensation temperature, costlier cooling source
may be required for condensation.
(c) Presence of air as a non-condensables reduces the efficiency of main con-
denser.
(d) Increases the possibility of contamination of products by air or other com-
ponents of atmosphere.

8.4.2.2 Determination of Vapour-Liquid Equilibrium (VLB) Data

VLE data must be determined for the given mixture for distillation and at the
operating pressure of distillation column. To find the VLE data, there are three
options. Priority wise these three options are given as follows:
(a) VLE data can be determined by experiment. If the operating pressure is
atmospheric or vacuum, then VLE data-experiment is easier. Only difficult
part is analysis. But if VLE data are required at high pressure, then this
experiment is difficult. This is the most reliable option or method for find-
ing the VLE data for the given mixture because the given mixture for distil-
lation may contain some unknown impurities which may not be considered
or ignored in other two options or methods given in the coming section.
(b) Find the VLE data for the given system from the literature, if they are avail-
able at the same operating pressure. In the literature VLE data are available
for the several thousand binary and many multicomponent systems. All
these data were determined by actual experiments. Major sources for these
data are as follows.
• Vapour-Liquid and Liquid - Liquid Equilibrium Data Collection,
DECHEMA Chemistry Data Series4, Volume-1, Parts 1 to 10, by
Process Engineering Channel

Gmehling and Onken (1977).

• Vapour-Liquid Equilibrium Data3 by Chu, Ju-chin et al (1956).
• Vapour-Liquid Equilibrium Data Bibliography6 by Wichterle, Linek
and Hala, Elsevier, The Netherlands, 1976.
• Vapour-Liquid Equilibrium Data at Normal Pressures7 by Boublik,
Polak, Wichterle ad Hala, Pergamon, Oxford, UK, 1968
• Perry's Chemical Engineers Handbook, 7,h Edition by Perry and
@ProcessEng

Green, McGraw-Hill, USA, 1998.

• Azeotropic Data8, 3 Vol., 2nd Ed. by Gmehling, J., Wiley-VCH,
Germany, 2004.
(c) VLE data can be determined theoretically by using phase equilibrium equa-
tion. In the given feed mixture for distillation, if all components are from
the same group and operating pressure for distillation is atmospheric then
 Process Design of Distillation Columns

usually vapour-liquid equilibrium for such mixture can be assumed as ideal

vapour-liquid equilibrium. Example: Feed mixture of benzene and toluene
at atmospheric pressure.
For the ideal VLE, Roult's law is applicable.
yxpt = Xj /?(sat (Roult's law) (8.1)
where, = Mole fraction of component i in vapour phase
Xj = Mole fraction of component i in liquid phase
p, = Operating pressure, kPa
Sat
Pj = Vapour pressure of pure liquid i at the given temperature, kPa
General form of vapour-liquid equilibrium equation is y, = KjXj (8.2)
where, AT, = Equilibrium constant for component /
K - values for some hydrocarbons for the range of operating pressure from 101.3
kPa to 6000 kPa and for the range of operating temperature from -70oC to 200oC,
can be obtained from Dadyburjor chart (Refer Fig. 6.20).
For non ideal system VLE data is determined by following equation.
yieipl = xiyiprt (8.3)
where, 0, = Fugacity coefficient of component i
Yi = Activity coefficient of component i
Fugacity coefficient 0, represents the deviation of vapour phase from ideal gas
mixture. If the operating pressure is close to atmospheric pressure then vapour
phase can be assumed as ideal gas and 0, is unity. 0, can be calculated from an
appropriate equation of state like Redlich - Kwong equation, Peng-Robinson
equation, etc.
Activity coefficient Y represents the deviation of the behaviour of component
in given solution from the behaviour of same component in ideal solution. Y is a
function of temperature and liquid composition.
Y=f(Xi,T) (8-4)
Y is not dependent on pressure.
Activity coefficient Y can be determined by van Laar equation, UNIFAC method
or UNIQUAC method or by NRTL equation. Group contribution method like
UNIFAC method or UNIQUAC method are more reliable, but group contribu-
tion parameters are available for limited number of groups in literature.
For example,
For the mixture of ethane and propane, if VLE data are required at 10 atm a
Process Engineering Channel

pressure, then 0, ^ 1, but Y can be assumed equal to 1 for both components.

For the mixture of ethanol-ethyl iodine, if VLE data are required are at 1 atm
pressure, then for both components
0, = 1, but ft* 1.

8.4.3 Step 3: Degree of Separation

@ProcessEng

In case of binary distillation, specify xD and xw considering equilibrium limita-

tions in mind, (where xD = mole fraction of more volatile component in distillate
and xw = mole fraction of more volatile component in residue). Find the molar
flow rate of distillate D and molar flow rate of residue W, by using following two
material balance equations.
F=D+ W (8.5)
Fzf = Dxd + IL xw (8.6)
 386 Introduction to Process Engineering and Design

where Zf represents mole fraction of more volatile component in feed. Since feed
can be saturated liquid, saturated vapour or a mixture of liquid and vapour, sym-
bol zF is used. If it is only liquid, symbol xF can be used.
To establish the material balance in multicomponent distillation is not easy. In
case of multicomponent distillation, specify the distribution of two key components
in distillate (top product) and in residue (bottom product), considering equilibrium
limitations in mind. Exact distribution of non-key components in top product and
bottom predict is not possible at the starting of design. But, the same can be
determined approximately by Hegstebeck and Geddes equation9.
d;
log = A + C log oc( (8.7)
b
i j
where, <7, = Moles of /th component in distillate
b-, = Moles of /th component in residue
oc, = Relative volatility of /th component with respect to heavy key
component
A, C = Constants
Material balance calculations (approximate) for multicomponent distillation
is illustrated by following example.

Example 8.1
Feed mixture to a distillation column contains 30% «-hexane, 32% n-propane, 20%
n-butane and 18% u-pentane (by mole). Total flow rate of the feed is 100 kmol/h. If
butane and pentane are selected as light key and heavy key components, respectively
then (a) fix the operating pressure of distillation column and (b) find the product compo-
sitions.
Solution:
Generally the mixture of propane and butane is stored and sold as LPG (Liquefied
Petrolium Gas). Hence in that case, top product (mixture of propane and butane) must
be in liquid phase or a total condenser must be used. To facilitate the use of cooling
water as cooling medium in overhead total condenser, bubble point temperature of
distillate must be sufficiently greater than design temperature of cooling water from
cooling tower (say 320C). Also to facilitate the storage of liquid distillate without using
insulation and refrigeration system, bubble point temperature must be sufficiently greater
than atmospheric temperature.
Process Engineering Channel

Let bubble point of distillate = 60oC

For the first trial calculations, assuming that non-key components, propane will appear
in distillate only and hexane will appear in residue only. For the first trial calculations
material balance is assumed as follows.

Table 8.1 Material Balance of Distillation Column (I st Trial Calculations)

@ProcessEng

Component Distillate, kmol/h Residue, kmol/h

n-Propane 32.0
n-Butane 19.8 0.2
«-Pentane 0.2 17.8
«-Hexane — 30.0
Total 52.0 48.0
 Process Design of Distillation Columns

Bubble point temperature of distillate = 60oC. At bubble point, I/f, a", = 1

A'pf Apr + Kpc A'pc + A'py aBu = 1

xpr= — = 0.6154, Ap= — = 0.0038, Ar= — =0.381

Pr Pe Bu
52 52 52
0.6154 ATp,. + 0.0038 KPe + 0.381 KBu = 1 (a)
Here values of equilibrium constants are to be determined at the temperature 60oC
and operating pressure p, which is unknown. Hence by trial and error calculations find
the value of p, which satisfy Eq. (a). Values of equilibrium constants are determined by
using Fig. 6.20.
/?, =1500 kPa and t = 60oC
KPr = 1.4, KPe = 0.21, KBu = 0.52
I.Ki a,- = 0.6154 x 1.4 + 0.0038 x 0.21 + 0.381 x 0.52 = 1.06
At 1600 kPa and 60oC,
KV{ = 1.35, KPt = 0.2, KBu = 0.5
I/f,A, = 0.6154 x 1.35 + 0.0038 x 0.2 + 0.38 x 0.5 = 1.022 = 1
Operating pressure at top of column = 1600 kPa
Assume pressure drop in column = 30 kPa
Operating pressure at the base of column = 1630 kPa
To decide the distribution of non-key components Hegstebeck-Gedde's equation can
be used.
/
d,
log = A + Clogoc. (8.7)
b
\ i
where, = «avi = (-,t0p • ^/bottom)'72 (8-8)
To find out the average value of relative volatility, top and base (bottom) temperatures
of distillation column are to be determined.
For distillation column with total condenser, composition of overhead vapour and
distillate are same. Top most temperature of distillation column is equal to dew point
temperature of overhead vapour.
Top most temperature:

y.
At dew point, E—C = 1
K
i
Process Engineering Channel

0.6154 | 0.381 | 0.0038 =1

^Pr ^Bu ^Pc

At operating pressure p, = 1600 kPa and at temperature r, values of equilibrium con-
stants must be determined, where t is unknown.
For the first trial calculations. Let t = 750C
At 750C, A:pr = 1.65, A:Bu = 0.65 A:pc = 0.26
@ProcessEng

v » _ 0,6154 | 0.381 | 0.0038 = 0 974

K, 1.65 0.65 0.26

0
At 72 C, A:pr = 1.55, A:Bu = 0.6, ^ = 0.25

= 0-6154 | 0.381 | 0.0038 ^ j

K: 1.55 0.6 0.25
 Introduction to Process Engineering and Design

Bottom most temperature of distillation column is the bubble point of residue. Oper-
ating pressure at the base of column p', = 1630 kPa.
At bubble point Z AT,-.*,- = I

For residue, xRll = = 0.004 17, Xp„ = = 0.37, = — = 0.625

Bu
48 48 48
For the first trial calculations, let t = 150oC (and at 1630 kPa)
A'Bu = 1.9, Kpe = 0.95, 7:He = 0.52
= 0.004 17 x 1.9 + 0.37 x 0.95 + 0.625 x 0.52 = 0.684
Let t = 180oC. KBu = 2.5, Kpe = 1.3, A:He = 0.79
= 0.004 17 x 2.5 + 0.37 x 1.3 + 0.625 x 0.79 = 0.99 = 1

Table 8.2 Relative Volatilities

Feed Components '72° C '180"C

1.55 4.25
n-Propane = 6.20 = 3.270 4.500
0.25 1.3

0.6 2.5
/(-Butane (LK) = 2.40 = 1.923 2.150
0.25 1.3
/(-Pentane (HK) 1.00 1.000 1.000
0.11 079
n-Hexane = 0.44 = 0.6077 0.517
0.25 1.3

At 720C, KHc = 0.11 and at 180oC, KPr = 4.25.

For butane (light key component):
x
V.
log = A + C log oc.
Kbi

19.8
log = A + C log (2.15)
0.2
1.9956 =A +0.3324 C
For pentane (heavy key component)
Process Engineering Channel

0.2
log = A + C log (1)
17.8
-1.949 39 = A + 0
Solving two equations
A =-1.949 39
C= 11.8682
@ProcessEng

For propane:
x
'd.-
log = -1.949 39 + 11.8682 log (4.5)
\ b' y
/ x
d..
log = 5.803
Kbi
 Process Design of Distillation Columns

di_
= 635 331 (very high)
h
K i
di = 32 kmol/h
h, = 5 x 10_:i kmol/h = 0 kmol/h
For hexane:

log = -1.949 39 + 11.8682 log (0.517)

Kbi

= 4.47 x 10-6
b
K i
hi = 30 kmol/h
di = 1.34 x 10-4 kmol/h = 0 kmol/h
Propane does not appear in the residue and hexane does not appear in the distillate.
Hence, assumption made before deciding the distribution of components is valid. No
correction is required. So Table 8.1 shows the final product composition.

8.4.4 Step 4: Minimum Reflux Ratio

Determine the minimum reflux ratio Rin. It is the maximum reflux ratio for which
infinite number of trays are required for the desired separation. It corresponds to
the minimum condenser cooling load and the minimum reboiler heating load
required for the desired separation. In other words on decreasing reflux ratio, a
value of reflux ratio obtained for which desired separation become impossible, is
called minimum reflux ratio Rm.

8.4.4.1 Determination of Rm for Binary Distillation

(a) In case of binary distillation with ideal vapour-liquid equilibrium curve or

with the equilibrium curve which is always concave downward, Rm can be
calculated by any of the following equations'.
(i) For feed liquid at the bubble point or with, the saturated liquid feed
(i.e. for ^ = 1)

1 xD
Process Engineering Channel

Km = (8.9)
1 l
F 1 " Xr

where, oc = Average relative volatility

xD = Mole fraction of more volatile component in distillate
xF = Mole fraction of more volatile component in feed liquid

"g -
(8.10)
@ProcessEng

9 =
"g - Hl
Hg = Enthalpy of saturated vapour, kJ/kmol
Hf = Enthalpy of feed, kJ/kmol
H, = Ehthalpy of saturated liquid, kJ/kmol
 390 Introduction to Process Engineering and Design

(ii) For the saturated vapour feed or for feed vapour at dew point (i.e. for
<7 = 0)

1
- xD
R..,= -1 (8.11)
oc-1 yp 1
- yp
where, yF = Mole fraction of more volatile component in feed vapour
(iii) For any condition of feed (for any value of q), Rm can be determined by
solving the following equation.

Rm ZF + qxD oc[xD {q-\) + zF (Rm + ')] /0 ,_

(S.lZj
Rm(l- ZF) + q(l-xD) (Rm +1) (1 — Z/r) + (</ — 1) (1 — xD)

(b) In case of binary distillation with ideal or non ideal vapour-liquid equilib-
rium curve, minimum reflux ratio Rm can be determined by McCabe - Thiele
method (Ref. 1, 10). Following assumptions are made in McCabe - Thiele
method.
(i) For any equilibrium stage, molar latent heat of vaporization is equal to
molar letent heat of condensation.
(ii) Heat losses and heat of solution are negligible.
(iii) Total condenser is used but there is no subcooling. Condenser removes
all the latent heat from the overhead vapour but does not cool the re-
sulting liquid further.
Because of the first two assumptions, molar flow rate of liquid and molar flow
rate of vapour in each section (enriching section and stripping section) remain
constant throughout the section. Because of the third assumption, composition of
overhead vapour is equal to composition of distillate and also equal to composi-
tion of reflux.
L, G, L, G = constant
Xp = yi = x0
where, L,G = Molar flow rates of liquid and vapour respectively, in rectifica-
tion or enriching section, kmol/h.
L, G = Molar flow rate of liquid and vapour respectively in stripping or
exhausting section, kmol/h.
Process Engineering Channel

xD = Mole fraction of more volatile component in overhand vapour

x0 = Mole fraction of more volatile component in reflux.
Method for determining Rm by McCabe Thiele method:
(i) Draw the vapour - liquid equilibrium curve, y vs x. Also, draw the 45°
diagonal (x = y) line.
(ii) Mark the points x = y = xD, x = y = zF and x = y = xw on the 45° diagonal line.
(iii) Draw the ty-line. It starts from the point x = y = zF- The equation of ^-line is
@ProcessEng

q zF
y=—x—F— (8.13)
q-\ q-\

Slope of ty-line is
q-l
 Process Design of Distillation Columns

(iv) Draw the line from x = y = xD point to the point of intersection of ^-line and
equilibrium curve. Extend the same line to .y-axis. Intercept of this line
xD
gives the value of from which the value of Rm can be calculated.
Rm +1
But this procedure is valid for ideal vapour-liquid equilibrium curves and
also for non ideal vapour - liquid equilibrium curves except the curves as
shown in Figs 8.1(b) and (c). For the nonideal VLE curve like the
Fig. 8.1(b) tangent line of equilibrium curve decides the value of Rm. For
the nonideal VLE curve as shown in Fig. 8.1(c), a tangent operating line of
stripping section may set the value of Rm.

1
line

JlL.
ft*\ +
y

o
0 xw zF xD 1
X
(a)

1 ^-linc —
-VP
(7-line
Kn + " ^

"in + 1

0
0 xw zp xd 1 0 x,, xd 1
X X
Process Engineering Channel

(b) (c)

Fig. 8.1 Determination of Minimum Reflux Ratio for Binary Distillation

In case of multicomponent distillation, R^ can be determined by Underwood's

method1,11. In this method Rm is determined by solving the following two equa-
tions.
@ProcessEng

= k +1 (8.14)
oc. - ^

ot/Xif
= 1-4 (8.15)
OC; - $
 Introduction to Process Engineering and Design

where, oc,- = Average relative volatility of each component i with respect to heavy
key
xid = Mole fraction of component i in distillate
Xy = Mole fraction of component i in feed
q = Heat required to convert 1 mole of feed from its condition to a satu-
rated vapour divided by latent heat of vaporization,
ft = Constant

HG-HF
or <? = (8.10)
hg - Hl
Here = Ktop. ^ibottom)'72 (8-8)
Top most temperature of distillation column is dew point temperature of over-
head vapour. Bottom most temperature of distillation column is bubble point
temperature of residue.
For accuracy purpose, it is suggested that f), must be determined correct upto
four decimal places12, Eq., (8.15) may give many values of f), but correct value
of if is that belongs to the interval starting from 1 to the value of ocj K.

■& e {ocHK, ocLK} or ^LK > d > ^hk

where, ocLK = Relative volatility of light key component with respect to heavy
key component.
=
o^hk Relative volatility of heavy key component with respect to heavy
key component = 1

Example 8.2
Determine the minimum reflux ratio for the binary distillation at standard atmospheric
pressure based on the following data.
Feed = 100 kmol/h
Feed mixture: benzene - toluene
Mole fraction of benzene in feed = 0.4
Condition of feed = Saturated liquid
Mole fraction of benzene in distillate required = 0.99
Mole fraction of benzene in Residue required = 0.02
Average relative volatility = 2.25
Solution:
Process Engineering Channel

Benzene-toluene mixture behaves as an ideal mixture.

1 °t{l-xD)
Kn = (8.9)
-1 1 - Xp

1 0.99 2.25 (1-0.99)

R... =
@ProcessEng

2.25 - 1 0.4 1-0.4

Minimum reflux ratio Rn, = 1.95

Example 8.3
In the previous example, if the feed is at room temperature (30oC), what is the value of
Rm required?
 Process Design of Distillation Columns 393

Solution:
To find the value of Rin, first value of q must be determined.
HG - H F
(8 101
-
A + CpAt
(8.16)
Hg-Hl A
rF = Temperature of feed = 30oC
t/, = Bubble point temperature of feed
At bubble point:
IX;I K:I = 1

Lr, = 1 (for ideal VLB)

P,
Antoine equations13:

For benzene. In p..,, = 15.9008 2788.51

B
T-52.36

3096.52
For toluene. In pvT = 16.0137 -
T - 53.67
For the first trial calculations let tB = 27^, x,-
where TBi = boiling point of pure component i
Normal boiling point of benzene = 80.1 0C
Nomal boiling point of toluene = 110.6oC
For first trial calculations, tB = 0.4 x 80.1 + 0.6 x 110.6 = 98.40C (371.4 K)

i p = 15.9008
In i c nnno 2788.51 ,,
= 7.16
vR
371.4-52.36
pvB = 1287.54 torr, similarly
pvT = 527.4 ton-
Ijc.pv. = 0.4 x 1287.54 + 0.6 x 527.4 = 831.456 torr * 760 ton-
After trial and error calculations,
at tB = 95.30C,pvB = 1181.72 torr, pvr - 479.1 torr
Zx.pv. = 0.4 x 1181.72 + 0.6 x 479.1 = 760.15 torr
Bubble point of feed mixture, tBp = 95.30C ^ ^ + ^
Process Engineering Channel

Specific heat must be determined at the average temperature rav = = 62.650C

Table 8.3 Property Data of Benzene and Toluene

Component CL at 62.65 0C, kJ/(kmol • 0C) A at 95.30C, kJ/kmol

Benzene 146.96 29 391.3
Toluene 173.33 34 666.7
@ProcessEng

(Figure 3.11 and Table 3-179, of Ref. 14)

Average molar heat capacity, CL = ZCU x,-
CL = 146.96 x 0.4 + 173.33 x 0.6 = 162.78 kJ/(kmol • 0C)
Average latent heat
A = IXj A,- = 0.4 x 29 391.3 + 0.6 x 34 666.7
= 32 556.54 kJ/kmol
 394 Introduction to Process Engineering and Design

32 556.54 + 162.78 x (95.3 - 30)

q
~ 32 556.54
= 1.3265
Rm can be determined by following equation.

Rm ZF + qxD oc [x0 (^ - 1) + zF(Rm + I)]

(8.12)
Rm(\-ZF) + q(l-xD) (Rm +l)(i-ZF)+(q-l){l-xD)

(/?„, x 0.4)+ (1.3265 x 0.99 ) 2.25 [0.99(1.3265 - I) +0.4(^„ +1)]

/?„,(!-0.4)+ 1.3265 (1-0.99) (Rm + 1) (1 - 0.4) + (1.3265 - 1) (1 - 0.99)

0ARm + 1.313 235 0.7273 + 0.9 (Rm + 1)

_
0.6Rm + 0.013 265 0.6(/?„, + 1) + 0.003 265
After the trial and error calculations, for Rm = 1.67, LHS (1.9514) = RHS (1.95)
Use of a mathematical software such as Mathcad® or Maple® can be made to solve such
an equation.
Minimum reflux ratio, Rm = 1.67

Example 8.4
A distillation column is to separate 4750 mol/h of feed composed of 37% n-butane,
32%. Ao-pentane, 21% n-pentane and 10% n-hexane. The column operates at an average
pressure of 2 atm a and will produce a distillate product containing 95% n-butane and
5% Ao-pentane. The bottom product is allowed to contain no more than 570 mol/h of
n-butane. Use Underwood's method to determine the minimum reflux for the required
separation. Feed is 25% (by mole) vapour. Assume ideal vapour-liquid equilibrium. All
compositions are mole %.
Solution:
In this example, distillate composition is given. Hence residue composition can be de-
termined by material balance. Distillate composition indicates that /i-butane is light key
component and Ao-pentane is heavy key component.
Overall material balance:
F=D+W
4750 = D + W
Process Engineering Channel

n-butane balance:
0.37 x 4750 = 0.95D + 570
D = 1250 mol/h and W = 3500 mol/h

Table 8.4 Feed and Product Compositions

Component Feed Distillate Residue

@ProcessEng

mol % mol/h mol % mol/h mol % mol/h

n-butane 37 1757.5 95 1187.5 16.3 570.0
Ao-pentane 32 1520.0 5 62.5 41.6 1457.5
n-pentane 21 997.5 — — 28.5 997.5
n-hexane 10 475.0 — — 13.6 475.0
Total 100 4750.0 100 1250.0 100.0 3500.0
 Process Design of Distillation Columns

In Underwood's method, to find average relative volatilities, top most and bottom
most temperatures of distillation column are required.
Top most temperature = Dew point temperature of overhead vapour
At dew point

I V'' - = 1 (for ideal VLE)

P«»»

Ji= xiD (for t0ta^ condenser)

/
0.95 | 0.05'
x2= 1
PvnB Pvip J

where, pvnB = Vapour pressure of n-butane

pvjp = Vapour pressure of Ao-pentane.
Antoine equations9:
77-butane:

2154
J 9
v
InpvnR = 15.6782 -
T-34.42
where, 7 is temperature in K and pvnB is in ton-
Ao-pentane:

. 2348.67
In p.-p = 15.6338
T - 40.05
where pvip is in torr.
After a trial and error calculations dew point temperature can be determined.
For r = 220C = 295 K
PvnB = "650 torr = 2.17 atm
pvip = 615 torr = 0.8 atm

LHS = f^5 + 0:05lx2=l=RHS

V2.17 0.8 J
Dew point temperature of overhead vapour = 220C.
Bottom most temperature = Bubble point of residue
At bubble point:
Process Engineering Channel

Lv, p;'"' = p, (for ideal VLE)

0.163 pvnB + 0.416 pvip + 0.285 pvnp + 0.136pvnH = 2
Antoine equations9:

2477.07
In pvnp = 15.8333 -
T - 39.94

2697.55
@ProcessEng

In pvnH = 15.8366 -
7-48.78
where, pvnp = vapour pressure of n-pentane, torr
pvnp = vapour pressure of n-hexane, torr
7 = temperature, K
 Introduction to Process Engineering and Design

After a trial and error calculations, final T = 320 K or f = 470C

pvnB = 3403.3 torr = 4.478 atm
Pvip = 1399.95 torr = 1.842 atm
pvnp = 1084.1 torr = 1.426 atm
PvnH = 361.6 torr = 0.476 atm
LHS = 0.163 x 4.478 + 0.416 x 1.842 + 0.285 x 1.426 + 0.136 x 0.476
= 1.97 -2 = RHS

Table 8.5 Relative Volatilities Calculations

Pr Pv 1/2
Component -22 ' "47 c
av = (oc22 X oc47)
vhK Pv.vhK

2.17 4.478
//-butane (LK) = 2.7125 = 2.43 2.567
0.8 1.842

08
/.vo-pentane (HK) = 1
0.8

0.6 1.426
n-pentane = 0.75 = 0.774 0.762
0.8 1.842

0.173 0.476
n-hexane = 0.216 = 0.258 0.236
0.8 1.842

Underwood's equations:

= (8.14)
-ft
00 z
/ ifJ
and S —=\-q (8.15)
^ -0
Feed contains 25% vapour
HF = 0.25 x Hq + 0.75 x HL

Hr-Hp Hn -(0.25Hrr + 0.75/7,)

q=— -=— — (8.10)
Hg-Hl Hg-Hl
Process Engineering Channel

q = 0.75

2.567 x 0.37 1 x 0.32 0.762 x 0.21 0.236 x 0.1

1 1 1 — 0.25
2.567 — f) I-t3 0.762 - f) 0.236-d
For = 1.6045, f{-&) = 0.250 25 = LHS = 0.25 = RHS
Also 0 € {1,..., 2.567} (check)
@ProcessEng

^ixid
= /?m+l (8.14)

2.567 x 0.95 1 x 0.05

— R,., + 1
2.567 -1.6045 1-1.6045
Rm + 1 = 2.450 95
Rm = 1.450 95
 Process Design of Distillation Columns

8.4.5 Setp-5: Determination of Optimum Reflux Ratio

Ideally the reflux ratio which should be used for a new design should be optimum
or the most economical. Optimum reflux ratio is the value of reflux ratio for
which the total cost of distillation is minimum. Value of optimum reflux ratio
depends on the type of system or feed mixture, specified separation and operat-
ing conditions. Change in desired purity of products changes the value of opti-
mum reflux ratio and also the minimum reflux ratio. Based on cost analysis,
optimum reflux ratio is defined as that value of reflux ratio which causes the total
variable annual cost (annual fixed charges plus annual operating costs) to be a
minimum.
At the minimum reflux ratio, distillation column requires infinite number of
trays or infinite packing height and consequently the fixed cost is infinite but
minimum operating cost (cost for the heating medium of reboiler, cooling me-
dium for the condenser, power for reflux
pump, etc. minimum). As the reflux ratio
Total
increases above the minimum, number of cost /
trays required or packing height required
rapidly decreases but column diameter,
sizes of condenser and reboiler, and size /*- Operating cost
of reflux pump increases. Despite the in-
crease in column diameter and increase in
Fixed cost
sizes of condenser and reboiler, the annual
fixed cost for the distillation goes down as
Optimum R
the increase in reflux ratio above minimum y
results in saving in tower height which
more than offsets other fixed costs. This is Reflux ratio (R)
not continued as the reflux ratio increases Fig. 8.2 Determination of Optimum
further. At certain value of reflux ratio the Reflux Ratio
tray requirement or height of packing re-
quirement approaches a near constant value characteristic of the minimum trays
or height requirement, while the diameter and sizes of heat exchangers continue
to increase and hence at some value of reflux ratio, fixed cost passes through
minimum point. Increase in the value of reflux ratio further increases the fixed
Process Engineering Channel

cost again. Operating cost always increases with increase in reflux ratio. The
total annual cost, which is sum of operating and fixed costs, must therefore pass
through a minimum at the optimum reflux ratio.
For many hydrocarbon distillations, optimum reflux ratio lie between 1.2 to
1.5 times the minimum reflux ratio. But for the difficult distillation, like distilla-
tion of acetic acid - water system, optimum reflux ratios are higher than 1.5. For
@ProcessEng

azeotropic mixtures, reflux ratio is usually high. For the optimum design of dis-
tillation column, optimum values of reflux ratio, operating pressure and purity of
products must be determined.

8.4.5. / Determination of Theoretical Stages

To determine the number of theoretical stages or equilibrium stages, required for

 Introduction to Process Engineering and Design

desired separation, many methods are available. But they can be broadly divided
in two groups.
(a) Methods valid for binary distillation
(b) Methods valid for multicomponent distillation
(a) Methods Valid for Binary Distillation: Both short cut methods and detailed
methods are available. Short cut methods available for binary distillation are
Fensky's equation1. Smoker's equation9, etc. Detailed methods available for bi-
nary distillation are McCabe-Thiele method, Ponchon-Savarit method1, etc. Also
to find the number of theoretical stages for high purity products, Kremser equa-
tion1, Robinson and Gilliland equation9, etc. are available.
A. McCabe-Thiele Method1'10
Assumptions made in McCabe-Theile method are discussed in the previous sec-
tion. McCabe-Thiele method cannot be used for the following cases.
(i) Cases where heat of solution or heat losses are significantly large. Exam-
ple: Separation of ammonia from dilute aqueous solution by distillation.
(ii) For the cases in which high purity of products are required. In such cases
other method is used to support the McCabe-Thiele method. However, for
the same cases one can use only McCabe-Thiele method, but more than
one graphs are to be drawn at different scales. Stepwise procedure for
applying McCabe-Thiele method is as follows.
1. Draw the vapour liquid equilibrium curve from the VLE data available
at the operating pressure of distillation column.
2. Mark the point xD, zF, and xw on 45° diagonal line.

Cj Z.p
3. Draw the ^-line. The equation of <?-line is y = x -
q-\ q-\

(8 13)
- .
It starts from x = y = Zf point and its slope is ql{q -1), where q is the
heat required to convert the feed from its condition to saturated vapour
divided by molar latent heat of vaporization.
4. Determine the mimimum reflux ratio Rm.
5. Select the value of actual reflux ratio R. Draw the enriching section
operating line. The equation of this line is
Process Engineering Channel

R , xd Q
y= x-i (8.17)
' R +l R + l

This line starts from x = y = xD point. Its intercept is xJiR + 1)

6. Draw the stripping or exhausting section operating line. It starts from
the point x = y = xw pass through the point of intersection of enriching
@ProcessEng

section operating line and the q line.

7. Starting from xD to xw or from xw to xD, carry out the stepwise con-
struction between operating lines and equilibrium curve. Total number
of steps is equal to number of theoretical or equilibrium stages, re-
quired for the desired separation.
 Process Design of Distillation Columns

Example 8.5
Acetic acid is to be separated from a process stream containing 80% acetic acid and 20%
water (by mass) by continuous distillation at atmospheric pressure. Concentration of
water in bottom product (pure accetic acid) should not be greater than 50 ppm. Top
product (distillate) contains 80% water and 20% acetic acid (by mass). The feed is liquid
at 30oC. Estimate the number of theoretical stages required.

Table 8.6 Vapour-Liquid Equilibrium Data (t-x-y Data) at 101.325 kPa

Temperature, 0C Mole fraction of Mole fraction of

water in liquid, x water in vapour, y

118.3 0 0
110.6 0.1881 0.3063
107.8 0.3084 0.4467
105.2 0.4498 0.5973
104.3 0.5195 0.6580
103.5 0.5824 0.7112
102.8 0.6750 0.7797
102.1 0.7261 0.8239
101.5 0.7951 0.8671
100.8 0.8556 0.9042
100.8 0.8787 0.9186
100.5 0.9134 0.9409
100.2 0.9578 0.9708
100.0 1.0000 1.0000

(Table 13.1 of Ref. 14)

Solution:
Feed contains 20% water and 80% acetic acid by mass. Molar mass of water is 18 and
molar mass of acetic acid is 60. Water is the lighter component.
Mole fraction of water in feed.
20
18
X
F= = 0.4545
20 80
+
Process Engineering Channel

18 60
Mole fraction of water in distillate

80
18
X
D- = 0.9302
'SO' 20
+
18 60
@ProcessEng

Mole fraction of water in bottom product

50 x 10_6/18
A,- = 7 = 1.666 x lO-4
-6 1 - 50 x 10 -6
50x10
18 60
 400 Introduction to Process Engineering and Design

<7-line:
Feed is liquid at 30oC temperature. From t-x-y data, bubble point of feed can be easily
determined, t = bubble point temperature of feed when x = xF. For x = 0.4545 corre-
sponding value of r = 105.14oC.
Bubble point of feed = 105.14oC
Latent heat of water at 105.140C, A,,, = 40 392 kJ/kmol
Latent heat of acetic acid at 105.14oC, A,a = 20 096.6 kJ/kmol

30 + 105.14
Specific heat at ^ = 67.570C

CpW = 75.36 kJ/(kmol ■ 0C)

CM = 131.88 kJ/(kmol • 0C)
Latent heat of feed, AF = 0.4545 x 40 392 + (1 - 0.4545) x 20 096.6 = 29 320.86 kJ/kmol
Mean specific heat of feed,
CpF = 0.4545 x 75.36 + (1 - 0.4545) x 131.88 = 106.19 kJ/(kmol • 0C)

Hg-Hf (Hg-Hl) + (Hl-Hf) ?iF + CpF{tBP-tF)

q=
HG - H L HQ - H L -V

29 320.86 + 106.19 (105.14 - 30)

q
~ 29 320.86
q = 1.272
Equation of r/-line:

q ZF
y=-L-x (8.13)
q-\ q-I

1.272 0.4545
y= v
0.272 0.272
y = 4.676 47A-- 1.67
^-line starts from x = y = zForx = y = 0.4545 point.
To find another point, when y = 0.6, a = 0.4854 using ^-line equation.
ry-Iine passes through (0.4854, 0.6) point.
Draw the r/-line in the graph. From Fig. (8.3), intercept for the operating line at mini-
Process Engineering Channel

X
D
mum reflux, 0.304 =
R
m +1
0.9302 =03

R
m
m +1
Rm = 2.1
K
Let R = 2R.,.=
m 2x2A=A.2
@ProcessEng

x
d 0.9302
= 0.1789
Z^ + l 4.2 + 1
On stagewise construction starting from x = y = xD, as shown in Fig. (8.3), up to
a = 0.02, number of theoretical or equilibrium stages required is 16 in which 8th theoreti-
cal stage from the top is corresponding to feed tray.
 Process Design of Distillation Columns

1.0
Feed point on 8th tray
No. of trays in
0.9 Enriching section = 7
No. of trays in
Stripping section = 9
0.8 Total theoretical trays = 16
ZF= 0.4545
xD = 0.9302
0.7
-line

0.6

0.5 /

0.4 z

0.
in + "

I/i 0^
R*\
o.i

0 X 0.1 0.2 0.3 0.4 4 0.5 0.6 0.7 0.8 0.9^ 1.0
Z X
xTr = 0.02 F D
.v
Fig. 8.3 McCabe-Thiele Diagram for Acetic Acid-Water System

Similarly, for the different values of R, number of equilibrium stages, N, required for
the same separation are determined and listed in the following table.

Table 8.7 Values of N for Different values of R/R

R'Rn 2 2.5 3 3.5 4

N 16 15.0 14 14.0 13.5

On increasing the value of R/Rm above 2, decrease in the value of N is very marginal.
Process Engineering Channel

Hence, /? = 2 Rm is considered to be nearer to the optimum value.

To find the number of equilibrium stages required to increase the purity of bottom
product (acetic acid) from x = 0.02 to xw = 1.666 x lO-4, Robinson and Gilliland equa-
tion9 can be used. For the stripping section, Robinson - Gilliland correlation is

(K'/S'-l)(x;/xw-l)
log +1
@ProcessEng

l/S'iK'-l)
Ns = + 1 (8.18)
log (K'/S')

where. Ns = Number of ideal stages required from the reference point x,' to xw
xw = Mole fraction of the more volatile component in the residue (bot-
tom product)
x/ = Mole fraction of more volatile component at the reference point
 Introduction to Process Engineering and Design

S' = slope of the bottom section operating line

A" = equilibrium constant for more volatile component
For the enriching section, Robinson and Gilliland correlation is

xr
(l-S) + ^-(S-K)
log
1-K
Nr = -1 (8.19)
S_
log
K
where, N,. = Number of ideal stages required from reference point xr to xj
Xj = Mole fraction of least volatile component in distillate
xr = Mole fraction of least volatile component at reference point
K= Equilibrium constant for the least volatile component
S = Slope of enriching section operating line
Here, in this example, Eq. (8.18) can be used to find the number of theoretical stages
required to purify the bottom product (acetic acid) from x/ = 0.02 to xw = 1.666 x K)-4.
5' = Slope of stripping section operating line = 1.2
K' = Slope of equilibrium line in the portion from 0.02 to 0. [From Fig. (8.3)]
= 2.5

[(2.5/1.2) - 1 Jl(0.02/1.666 x I0"4) - 1 ]

log +1
(1/1.2)(2.5-1)
N.. = +1
log (2.5/1.2)

log (104.174 95)

+ 1 = 7.33
log (2.083 33)
As discussed earlier, second graph with different scale can be drawn for finding
theoretical stages in the stripping section below x,. = 0.02. Actual plotting also gives
additional stages of 7.
Total number of theoretical stages required for desired separation = 16 + 7.33 = 23.33,
say 24.
Note: It can be seen that nearly 30% theoretical stages are required to reduce the water
content in the bottom product 0.02 mole % to 50 mg/L.
Process Engineering Channel

As stated earlier for the separation of pure acetic acid from its dilute aqueous solution
containing less than 30% by mass acetic acid, liquid-liquid extraction and azeotropic
distillation are more economical than ordinary distillation. Figure 8.4 shows that for
separating nearly pure water and pure acetic acid from 25.18% by mass acetic acid solu-
tion, 22 + 1 = 29 theoretical stages required for the value of reflux ratio R = 3.5823.
Comparison between the separation of 80% acetic acid solution and 25.18% acetetic
@ProcessEng

acid solution is given in following table.

Table 8.8 shows that for the separation of dilute solution about 20% more stages and
approximately three times higher condenser duty and reboiler duty are required. Hence,
for the separation of dilute aqueous acetic acid solution liquid-liquid extraction or
azeotropic distillation is more economical.
 Process Design of Distillation Columns

1.0 Feed point on 10th tray

No. of trays in q- ine
Enriching section = 9
0.9 No. of trays in
Stripping section = 13
Total theoretical trays = 22
0.8 ZF = 0.9083
*d = 0.99

0.7

0.6

y 0.5

0.4 7

in + "

«/•
n ♦ I oT /

0.1

o\o.l 0.2 0.3 0.4 0.5 0.6 0.7 Oi o^ ito

xr= 0.02 x z? xD

Fig. 8.4 McCabe-Thiele Diagram for Acetic Acid-Water System

Table 8.8 Comparison between Two Cases

Feed flow % by mass R N Distillate Condenser Reboiler

rate, kg/h acetic acid kg /h kJ/h duty, kW duty, kW

1SI 12 000 80 4.2 23 3000 1886.7 8 175.7 9 000

nnd 12000 25.18 3.5813 29 8978 2256.9 25 785.7 29 000
(Condenser duty, 0C = (R + I ) D Xav)

B. Use of Open Steam

Process Engineering Channel

While distilling an aqueous solution, if nonaqueous component is more volatile

then water is removed as residue product. In such a case instead of using separate
reboiler at bottom, heat required can be provided by admission of steam directly
to the bottom of tower. For the same value of reflux ratio and the given extent of
separation, use of open steam requires more number of trays or equilibrium stages.
However, it is usually cheaper than the separate reboiler system as it avoids fixed
cost and cleaning cost of reboiler. It also facilitates the use of lower pressure
@ProcessEng

steam as heating medium but with the use of open steam, condensate cannot be
recycled back to boiler feed tank.
Overall material balance,
F + S = D+W (8.20)
where, S = Molar flow rate of saturated steam entering at bottom, kmol/h
 Introduction to Process Engineering and Design

More volatile component balance

Fzf=DXD+WXW (8.6)
In this case stripping section operating line starts from (x = xw, y = 0) point and
has a slope equal to L/S or W/S.

where, L = Molar flow rate of liquid in stripping section, kmol/h

= W, molar flow rate of residue, kmol/h
If superheated steam is used as open steam, then S and L are calculated by the
following equations.

A
( H- //sat
sat
5 = 5.S 1+ ' (8.21)
AM

L=S-Ss+W (8.22)
where, Ss = Molar flow rate of superheated steam, kmol/h
Hs = Enthalpy of superheated steam, kl/mol
//sal = Enthalpy of saturated steam, kJ/mol
A = Latent heat of vaporization at operating temperature, kJ/kg
M = Molar mass of water = 18.0153 kg/kmol

Example 8.6
Aqueous solution of ethanol contains 6 % by mass ethanol. It is to be concentrated in the
distillation column to 30 % ethanol (by mass). Open steam, saturated at 80 kPa g pressure
will be used for the distillation column. Feed flow rate is 5000 kg/h and it is saturated
liquid at its bubble point. Residue should not contain more than 0.02 mass per cent
ethanol. Sparging steam flow is 0.2 kg per kg of feed. Calculate the number of theoreti-
cal stages required for the desired separation.
Solution:
Basis: 5000 kg/h feed
5000 x 0.06 5000 x 0.94
F= + = 6.52 + 261.11 = 267.63 kmol/h
46 18
5 = (0.2 x 5000)/18 = 55.556 kmol/h
F+S = D+ W (8.20)
D + W = 323.186 kmol/h
Process Engineering Channel

(0.06/46)
zF = = 0.024 37
(0.06/46)+ (0.94/18)

(0.3/46)
xD = = 0.1436
(0.3/46)+ (0.7/18)

0.0002/46
•% - = 7.827 x 10-5
@ProcessEng

(0.0002/46)+ (0.9998/18)
Fzf = D xD +Wxw (8.6)
-5
267.63 x 0.024 37 = 0.1436 D + 7.827 lO W
5
6.522 =0.1436 £ + 7.827 x lO- (323.186-D)
D = 45.266 kmol/h
IV = 277.92 kmol/h
 Process Design of Distillation Columns

Feed is saturated liquid at its bubble point.

Hence, <7 = 1

L = L + Fq = L + F= W

G = G + F{q- 1) = G
S = G = G = 55.556 kmol/h
G = (R + I) D
55.556 = (R + 1)45.266
R = 0.2273

Table 8.9 Equilibrium Data for Ethanol-Water System at 101.3 kPa

x 0.019 0.0721 0.0966 0.1238 0.1661

>' 0.17 0.3891 0.4375 0.4704 0.5089
(Table 13.1 of Ref. 14)

Intercept of enriching section

operating line = xD/(R + 1) = 0.1436/(0.2273 + 1) = 0.117

- 277 92
Slope of stripping section operating line = L/S = VF/S = ^ =5

Stripping section operating line starts from (xw, 0) point.

From Fig. 8.5, number of equilibrium stages required is N = 1.

0.005 0.01 0.015

0.15

*♦I
0.1
Detail at "A

0.05

OV-Av
Process Engineering Channel

0.4

0.3 7- mc
-v
0.2

R*1
@ProcessEng

"A 0. .0 ^0.03 0..040.05 0.06 0.070.08 0.09 0.1 0.11 0.12 0.130.1^15
.r..,= 7.827 x lO" 5 zF= 0.024 37 xD= 0.14366 A

Fig. 8.5 McCabe-Thiele Diagram for Steam Stripping of Ethanol-Water Solution

 Introduction to Process Engineering and Design

C. Ponchon-Savarit Method
This method is more rigorous than McCabe-Thile method. This method requires
detailed enthalpy data and it is particularly applied to a binary system in which
heat of solution is significant. This method is explained by following illustration.

Example 8.7
Determine the minimum reflux ratio and number of theoretical stages required for the
distillation column of ammonia-water absorption refrigeration plant based on following
data. Also find the heat duty of overhead condenser (pc and reboiler heat duty <prj for the
given value of reflux ratio R.
Data: (Example 8.4 of Ref. 13)
(a) Feed:
Feed is strong aqueous (SA) ammonia solution which enters the distillation column
at 102.5oC
Enthalpy of feed = 325.2 kJ/kg
Mass % of ammonia in SA = 36.3%
Feed flow rate = 7523.28 kg/h
(b) Distillate: 100% pure ammonia in the form of saturated liquid at 40oC
(c) Residue: Weak aqueous (WA) solution of ammonia, having 29.8 % strength by
mass.
(d) Operating pressure of column = 1555.5 kPa a
(e) Cooling water at 320C is used as cooling medium in overhead condenser and satu-
rated steam at 3 bar a is used as heating medium in generator (reboiler).
(f) H-x-y data (Fig. 5.19, of Ref. 13)

Table 8.10 Enthalpies of Saturated Liquid and Vapour Mixtures

x,y Hl, kJ/kmol Hc, kJ/kmol

0 15 480.7 50 310.7
0.15 10 887.3 48 194.8
0.30 7 519.0 45 665.1
0.40 5 808.0 43 985.9
0.45 5 614.9 42 997.0
0.50 4 900.0 42 078.8
Process Engineering Channel

0.60 4 523.2 40 024.9

0.70 5 189.7 38 234.3
0.80 6 449.3 36 122.0
0.90 7 181.6 33 334.7
1.00 9 159.6 27 832.4

where,
@ProcessEng

Hl = Enthalpy of saturated liquid at 1555.5 kPa a pressure, kJ/kmol

Hg = Enthalpy of saturated vapour at 1555.5 kPa a pressure, kJ/kmol
x, y = Mole fraction of ammonia in ammonia-water liquid solution and in ammo-
nia-steam mixture, respectively.
(g) VLB data at p, = 1555.5 kPa a
(Table 3.23 and Table 3.24 of Ref. 14)
 Process Design of Distillation Columns

Table 8.1 I Equilibrium Data for Ammonia-Water System

X
0 0
0.30 0.9120
0.35 0.9456
0.40 0.9690
0.45 0.9800
0.50 0.9880
0.60 0.9950
0.75 0.9980
1.00 1.0000

(h) Actual or operating reflux ratio, /? = 0.3137 which is nearly equal to 0.08 kg per kg
ammonia (as NH3) in the feed.
Solution:
Material balance
Feed flow rate, mF = 7523.28 kg/h
0.363/17
x,, = = 0.3763
(0.363/17)+ (0.637/18)
Average molar mass of feed
Mav = I M, X;
Mav = 17 (0.3763) + 18 (1 - 0.3763) = 17.6237 kg/kmol

7523 28
F= - = 426.88 kmol/h
17.6237

0.298/17
;%= =0.31
(0.298/17)+ (0.702/18)
X
D— '
F = D +W ox 426.88 = D + W (a)
Ammonia balance:
Fxf = D xD+W xw
426.88 x 0.3763 = D + 0.31 W
Process Engineering Channel

D = 41.0176 kmol/h, Vk = 385.8624 kmol/h

Minimum reflux ratio, Rin:
To find Rm, '\x\ H - x, y diagram, draw the tie-lines. (Line connecting equilibrium
values of x and y is called tie-line.) Extend the tie lines and allow to intersect x=x0 and
x = xw lines. Intersection point with x = xD is represented as AD and with x = x^ as A Vk.
Extended tie lines which give the farthest locations of ADm and AW,,, and are corre-
sponding to minimum reflux ratio. But if x, y equilibrium curve is everywhere concave
@ProcessEng

downward, then a tie line which when extended passes through F corresponds to mini-
mum amount of reflux.
Herex, y equilibrium curve is everywhere concave downward. Hence, the minimum
reflux ratio is established by the tie line which when extended passes through F.
Mark the point Din H-x, y diagram. x/? = 0.3763 and HF = 325.2 x [1.6231 = 5731.23
kJ/kmol.
 408 Introduction to Process Engineering and Design

Find the tie line which when extended, passes through point F. One method is, draw
the two nearest tie lines from the given equilibrium data. Here, these two tie lines are
(i) x = 0.35 and y = 0.9456, and (ii) = 0.4 and y = 0.969. Then draw the line having
average slope and passes through point F. Extend this tie line and allow it to intersect
x = xD line. Intersection point is AD,,,. From Fig. 8.4 at AD,,,, (p,„ = 31 818 kJ/kmol.

Vm - H g |
R.., =
^ci-^o

31 818-27 832.4
Rm = = 0.213 44
27 832.4-9159.6
/?„, = 0.213 44
Actual R is 0.3137. Thus actual reflux ratio is 1.47 times the minimum reflux ratio.
For R = 0.3137

R =
#ci -hlo
(p-21 832.4
0.3137 =
27 832.4-9159.6

(p = 33 690 kJ/kmol
Mark AD onx = xD line corresponding to the value of (p.
FHf = D(p+ W(p'
426.88 x 5731.23 = 41.0176 x 33 690 + 385.8624 (p'
(p' = 2759.18 kJ/kmol
Mark AW on x = xw line corresponding to value of cp'. AD, F and AW are on the same
line. In Fig. (8.6(a)), AD at xD = 1, (p = 33 690 kJ/kmol and AW at xw = 0.31, (p' =
2759.18 kJ/kmol are plotted. Auxiliary random lines from the A points are drawn and
allowed to intersect the saturated vapour and saturated liquid curves at values of y andx,
respectively. These (x, y) points are the points of operating curves. Operating curves are
plotted in Fig. 8.6(b). Stagewise construction fromxD to xw between equilibrium curve
and operating curve gives number of theoretical stages required for the desired separa-
tion.

Table 8.12 x. y Values for Enriching Section Operating Curve and Stripping Section Operating
Process Engineering Channel

Curve

Enriching Stripping
X y X y
1.00 1.000 0.381 0.942
0.95 0.990 0.373 0.900
0.90 0.982 0.360 0.800
@ProcessEng

0.80 0.970 0.350 0.700

0.70 0.962 0.339 0.600
0.60 0.955 0.329 0.500
0.50 0.949 0.324 0.400
0.381 0.942 0.310 0.310
 Process Design of Distillation Columns 409

56000 n
Detail "A
52000
Auxiliary lines for determining D
48000 operating curve
44000
40000 0.95 1.00
A
36000
32000 /.)
28000
24000
»= 1555.5 kPa
20000
6000
2000
lie lines
8000
4000 Auxiliary lines for determining
ir Feed operating curve
0,10 0,20 0.30 0.40 0,50 0,60 0.70 0,80 0.90 1.00

(a) Enthalpy-Concentration Diagram for Aqueous Ammonia Solution

1.00

0.90 i Enrichit tg section

.... operatin g curve
(4 stage s)
0.80 Fmnlihriiim rnrvf* ....
1- inc
.1
Stripping section
0.70 operating curve
(5.36 slaues)
0.60 i
l
0.50 Ki
/
0.40
Process Engineering Channel

Feed
0.30

P = 1555 5 kPa a
0.20

0.10
@ProcessEng

Z
>^ F = 0.3763
0
0 0.10 0.20 0.3fKv 0.40 0.50 0.60 0.70 0.80 0.90 1.00
xw = 0.31
x
fb) Theoretical Stage Calculations for Distillation of Aqueous Ammonia Solution
Fig. 8.6 Separation of Ammonia from Aqueous Solution
 Introduction to Process Engineering and Design

Here stage wise construction is started from xD = 0.999 72 to.% = 0.31. Total number of
theoretical stages required (as shown in Fig. 8.6(b)) is 5.36.
N = 5.36.

(p = HD+— =9\59.6 +
D 41.0176
(pc = 1006 178.1 kJ/h = 279.493 kW

Qb QB
, H = 7347 86
1 = «-W ' "" 385.8624
(pB = 1770 599.1 kJ/h = 491.83 kW

(b) Methods Valid for Multicomponent Distillation: To determine by number

of theoretical stages or equilibrium stages required for desired separation in
multicomponent distillation many methods are available. None of them is totally
reliable. Hence, for a new case of distillation, it is recommended to use more than
one method for the determination of theoretical stages. Also it is better to design
the distillation column, first for pilot plant and then modify the design based on
the results of pilot plant column rather than designing the column directly for the
commercial scale plant. Methods available for multicomponent distillation can
be broadly divided into two groups.
(i) Short cut methods: FUG method, FUE method, Smith-Brinkley method,
etc.
(ii) Rigorous methods: Lewis Malheson method, Thiele-Geddes method,
Relaxation methods, Tridiagonal Matrix method, Linear Algebra methods,
etc:
A. FUG Method (Fenskey-Underwood-Gilliiand's Method):
It is the most widely used short cut method for determining number of equilib-
rium stages for multicomponent distillation.
In this method first minimum reflux ratio Rin is determined by Underwood's
method, which was explained in Sec. 8.4.4.1.
Then Fenskey's equation is used to find the minimum number of theoretical
stages required for the desired separation.
Fenskey's equation
Process Engineering Channel

/ \ / \
X X
LK HK
log
. XHK ) d v X
LK ) b
(8.23)
logoc LK

where, ocLK = Average relative volatility of light key with respect to heavy key
@ProcessEng

(x^, xhk)(i = Mole fraction of light key and heavy key in distillate
(XLK' xHK^h = Mole fraction of light key and heavy key in residue
If there is a wide difference in the values of °^LK at the top most temperature
and at bottom most temperature, then the use of following equation in Fenskey's
equation gives lesser value of Nm than actual Nm required,
= X
^LK LK, top ^LK, bottom)172 (^)
 Process Design of Distillation Columns

In such case it is recommended to find the following equation.

^LK = (^LK, top X ^LK, feed >< ^LK, bottom)173 (8.24)

where ocLK feed = relative volatility of light key with respect to heavy key at the

bubble point of feed.

After finding the values of Rm and Nm, number of theoretical stages required
or number of equilibrium stages required for desired separation can be deter-
mined by Gilliland's correlation. It was originally presented in terms of graph.
Many attempts are made to represent Gilliland's correlation analytically. One of
the analytical equations for Gilliland's correlation is developed by Malokanov14.

N - Nm 1 + 54.41// V/-1
m = = 1 - exp (8.25)
N+l 11 + 117.21// 0.5
¥

R R
~ w
where, v= (8.26)
R+ \

Example 8.8
Determine the number of theoretical stages required for desired separation by FUG method
for the case given in Example 8.4.
Solution:
Minimum reflux ratio determined by Underwood's method in the Example 8.4.
7?,,, = 1.4509
Using Fenskey's equation to find the minimum number of theoretical stages required for
desired separation, Nm for total reflux.

X LK X HK
log
X
HK
Jd \ LK /
".n = (8.23)
log'XLK

0.95 ) f 0.416 )
log
0.05 j 10.163 J
Nm =
log (2.567)
Process Engineering Channel

TV =4.117

Table 8.13 Values of N for Different Values of R

R ¥ AN) N

1.7 0.092 26 0.5616 10.67

@ProcessEng

2.0 0.183 03 0.4752 8.75

2.5 0.299 74 0.3811 7.27
3.0 0.387 30 0.3198 6.52
3.5 0.455 36 0.2761 6.07
4.0 0.509 82 0.2433 5.76
 Introduction to Process Engineering and Design

Gilliland's correlation,
N-N 1+54.41// V/-1
f(N) = = 1 -exp (8.25)
J{
' N+\ 11+117.21// 0.5
¥

R-R..
where. y/ = (8.26)
R+l
Refer Table 8.13 for the calculated results.
Above the value of reflux ratio R = 3, there is a tapering in values of N. Hence, the
optimum reflux ratio is nearer to R = 3.
Let actual reflux ratio, R = 3
Number of theoretical stages required for the desired separation N = 6.52.

Example 8.9
A fatty acid mixture contains 11% palmitic acid, 4% stearic acid, 28.5% oleic acid and
rest linoleic acid (by mass). It is to be distilled to separate in pure components in distil-
lation columns operating at 2 torr absolute at top.

Table 8.14 Pressure vs. Boiling Point Data of Fatty Acids

Absolute Pressure Boiling Point, 0C

kPa torr Palmitic acid Stearic acid Oleic acid Linoleic acid
0.133 1 167.4 183.6 177.6 178.5
0.267 2 179.0 195.9 189.5 190.1
0.533 4 192.2 209.2 202.6 202.8
1.07 8 206.1 224.1 217.0 216.9
2.13 16 221.5 240.0 232.9 232.6
4.27 32 238.4 257.1 250.6 250.0
8.53 64 257.1 276.8 270.3 269.7
17.1 128 278.7 299.7 292.5 291.9
34.1 256 303.6 324.8 317.7 317.2
68.3 512 332.6 355.2 346.5 346.5
101.325 760 351.5 376.1 364.9 365.2

(Table 2 of Ref.: 15)

Table 8.15 Chemical Formulas and Molar Masses of Fatty Acids

Process Engineering Channel

Fatty acid Chemical Formula Molar mass

Palmitic acid CieF^CL 256.42

Stearic acid CI8H3602 284.48
Oleic acid C|8H3402 282.46
Linoleic acid CigHjjO-, 280.45
@ProcessEng

Feed is a saturated liquid. Determine the number of theoretical stages required for the
desired separation.
Solution:
Boiling points of oleic acid and linoleic acid are very close. Hence they are near impos-
sible or very difficult to separate by distillation. It is planned to separate the following
three products from the feed mixture.
 Process Design of Distillation Columns

To Vaccum To Vaccum
System System

CW

c
DO]
Oleic Acid
+
Palmitic Acid Linoleic Acid
Fatty Acid
Mixture

Dc<]—>- Stearic Acid

Fig. 8.7(a) Separation of Fatty Acids

Products Purity in % by mole

1. Palmitic acid 99%
2. Mixture of linoleic and oleic acids 91% (Combinedly)
3. Stearic acid 95%
Two distillation columns are required. First column will separate 99% by mole pure
palmitic acid as top product and remaining as bottom product. Second column will give
97% by mole pure (combinedly) mixture of linoleic and oleic acid as the top product and
Process Engineering Channel

95% by mole stearic acid as the bottom product. Both columns will be operated under
vacuum and operating pressure at the top of both columns will be 2 torr a.
(a) Determination of number of theoretical stages required for first distillation
column:
Operating pressure at top: 2 torr a. Top product is nearly pure palmitic acid. At 1790C
vapour pressure of palmitic acid is 2 torr (Table 8.14). Hence top temperature of column
will be very close to 1790C. Let operating pressure at the base of first column is 30 torr
@ProcessEng

a. (This is decided based on one trial calculation). Bottom most temperature of distilla-
tion column is bubble point temperature of residue. To carry out the material balance
and to find the feed composition in mole %, let the feed flow rate be 1000 kg/h (basis).
Mass flow rate of feed, mF = 1000 kg/h
 Introduction to Process Engineering and Design

Table 8.16 Feed Composition

Component mass % Molar mass kmol/h mole %

Palmitic acid II 256.42 0.428 98 11.94
Stearicacid 4 284.48 0.140 61 3.91
Oleicacid 28.5 282.46 1.008 99 28.08
Linoleic acid 56.5 280.45 2.014 62 56.07
Total 100.00 3.5932 100.00

Table 8.17 Composition of Distillate and Residue of 1st Column

Component Distillate, D Bottom, W

kmol/h mole % kmol/h mole %

Palmitic acid 0.3971 99 0.031 88 1

Stearicacid — — 0.14061 4.4
Oleicacid 0.002 0.5 1.006 99 31.55
Linoleic acid 0.002 0.5 2.012 62 63.05
Total 0.4011 100.0 3.1921 100.00

Vapour pressures of oleie acid and linoleic acid are nearly same. Hence, in distillation
calculations they are considered as one product. For first column palmitic acid is the
light key and mixture of oleic acid - linoleic acid is the heavy key.
Component balance around 1st distillation column: Palmitic acid balance.
0.1194 F = 0.99 D + 0.01 W
Let mole % of palmitic acid in residue = 1%.
0.1194x3.5932 =0.99 D +0.01 (3.5932-D)
D = 0.4011 kmol/h, IV = 3.1921 kmol/h
Let mole % of heavy key in distillate =1%
Resulting material balance is shown in Table 8.17.
At bubble point temperature of residue

ZXwiPvi =P, = W torr

Trial temperature = 250oC

Table 8.18 Vapour Pressures as Read from Fig. 8.7(b)

Process Engineering Channel

Vapour pressure torr

0
Component At 179 C, torr At 250oC, torr
Palmitic acid 2 51.71
Stearic acid 0.714 23.29
Linoleic acid/Oleic acid 0.903 31.43
@ProcessEng

Using Fig. 8.7(b) and Table 8.17,

0.01 x 51.71 + 0.044 x 23.29 + (0.3155 + 0.6305) x 31.43 = 31.27 torr s 30 torr
Hence bottom most temperature of 1st distillation column = 250oC
 Process Design of Distillation Columns

70

60
/ ^
fa 50 ' i/ J
o

40 // rr
-l/r/
. CJ
2
c/-
B
a. /M
30
3
O
n.
20

10

0
160 180 200 220 240 260 280

Boiling point, 0C

Fig. 8.7(b) Vapour Pressures of Fatty Acids based on Table 8.14

Table 8.19 Relative Volatilities Calculations

Component a
top ^bottom «av
Palmitic acid (LK) 2.2148 1.6452 1.9089
Stearic acid 0.7907 0.741 0.7654
Linoleic acid/Oleic acid (HK) 1 1 1

Here FUG method is used to find the number of theoretical stages required for desired
separation.
Minimum number of theoretical stages required by using Fenskey's method, Nm:

y
HK
log
k X
hk )d \ LK /
(8.23)
log 'LK
Process Engineering Channel

0.99 0.3155 + 0.6305

log
0.01 0.01 .
N.=
log (1.9089)

Nm = 14.144
@ProcessEng

Underwood's method:

oc,- Xu-
(8.15)
o=; - -0
 416 Introduction to Process Engineering and Design

Feed is saturated liquid. Hence q = 1

1.9089x0.1194 0.7654x0.0391 1 x (0.2808 + 0.5607)

=1-1=0
1.9089-13 0.7654-13 I -13

Solving by Mathcad,
For i3= 1.719 32, /(i3) = 0.001 s 0
Also,-de {1 1.9089}
oc x
( id
— Rn + 1
-13

1.9089x0.99 Ix (0.005+ 0.005)

+ = R... +
1.9089-13 I -13
= 8.9545
Gilliland's correlation

N - Nn. l + 54Ay/ yz-l

/"(AO = = I - exp (8.25)
•' N +1 11+117.21// j 0.5
¥

R — R,„
where, ¥= (8.26)
R+l

Table 8.20 Evaluation of Parameters

R ¥ m N

10 0.095 0.5586 33.31

12 0.234 0.4318 25.65
15 0.378 0.326 21.47
17 0.447 0.2813 20.07

Let, R= 15, for which N= 21.41 = 22

FUG method does not give information about feed tray location. Feed tray location
can be determined by using following equation (Kirkbride equation).
Process Engineering Channel

/ \ 2'
fw] X
HK f XhLK
log = 0.206 log (8.27)
[Ns; Id j v XLK ) f V XdHK y

where, Nr = Number of stages above the feed

Ns = Number of stages below the feed
/ N
3.1921) 0.2808 + 0.5607
@ProcessEng

0.01
log = 0.206 log
0.4011 J 0.1194 0.01

— =2.292
"s
 Process Design of Distillation Columns 417 |

Nr + Ns = 22
3.292 Ns = 22
Ns = 6.683 = 7, Nr = 15
Hence, seventh stage from bottom will be the feed stage.
For second distillation column W = F'. (As shown in Fig. 8.7(a)), where F' is molar
flow rate of feed to second distillation column.
Linoleic - Oleic acids balance around second column:
F' x (0.3155 + 0.6305) = 0.97 D' + 0.05 W
3.1921 x 0.946 = 0.97 D' +0.05 (3.1921 -D')
2.860 12 = 0.92 D'
D' = 3.1088 kmol/h, W = 0.0833 kmol/h

Table 8.21 Composition of Distillate and Residue of 2nd Column

Component Distillate D' Bottom, W

kmol/h mole % kmol/h mole %
Palmitic acid 0.0319 1.026 — —
Stearic acid 0.0615 1.978 0.0791 95
Oleic acid 1.0056 32.347 0.0014 1,68
Linoleic acid 2.0098 64.649 0.0028 3.36
Total 3.1088 100.000 0.0833 100.00

Operating pressure at the top of second column = 2 torr a.

Top most temperature of distillation column is dew point temperature of over head
vapour.
At dew point temperature
n

Pvi
Let top most temperature = 190.10C (Trial) y, = xD,
At 19().10C temperature, from Fig. 8.7(b) vapour pressure of components are as
follows.

Table 8.22 Vapour Pressures as Read from Fig. 8.7(b)

Process Engineering Channel

Vapour pressure, torr

o
Component At 190 C, torr At 268.20C, torr

Linoleic/oleic acid 2 63.5

Stearic acid 1.64 50
@ProcessEng

Table 8.23 Relative Volatilities Calculations

Component ^top "bottom «av

Linoleic/oleic acid 1.22 1.27 1.245
Stearic acid 1 1 1
 Introduction to Process Engineering and Design

For the calculations of number of theoretical stages required for desired separation
feed to second column can be approximated as binary system.

r = 3 l92ikmol^ D' = 3Kjgg w = 0.0833 ,

h h h
Zh = 0.946, xD = 0.97, .% = 0.05
Vapour-liquid equilibrium data can be determined by using following equation.

_ ax
y
~ l + (a-l)x

Table 8.24 VL£ Data for 2nd Column

X y
0 0
0.2 0.2374
0.4 0.4536
0.6 0.6513
0.8 0.8328
1.0 1.0000

Feed is saturated liquid q= \ .

From Fig. (8.7(c))

=0.4301
+1
Rm = 1.2553
R = 3x Rm = 3.7659

x
n 0 97
—R— = w = 0.203 53
R +1 4.7659

For R = 3.7659, number of theoretical stages required for desired separation, N = 33.
Feed tray location = 4 from top

B. Rigorous Methods:
Process Engineering Channel

Rigorous or detailed methods available for multicomponent distillation for find-

ing or verifying number of theoretical stages required for desired separation are
as follows.
(I) Lewis-Matheson method
(II) Theile-Geddes method
(III) Relaxation methods
@ProcessEng

(IV) Equation tearing procedures using tridigonal matrix algorithm.

Among these methods only Lewis-Matheson method calculate the number of
theoretical stages. In other methods number of equilibrium stages required above
and below the feed point must be specified by the user. In other methods, for the
given number of theoretical stages, product compositions are determined.
 Process Design of Distillation Columns 419

"A"
.0 Feed point on 4th tray
a-linc
No. of trays in
enriching section = 3
0,9 No. of trays in
stripping section = 30
Total theoretical trays = 33
Zf = 0.946
.vD = 0.970
xw = 0.050
0,7

>' 0.5
«..
«_■» I
q - line

0.3

/.• . i 0.2
I Detail= "A^

0.1 A
zp D

0 \0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 l-fl.O
a-w = 0.05
zp
Fig. 8.7(c) McCabe-Thiele Diagram for Second Column

(I) Lewis-Matheson Method12

In this method, constant molar overflow is assumed. In other words, in this method
it is assumed that for each stage, molar latent heat of vaporization of liquid phase
is equal to latent heat of condensation of vapour phase. Hence moles of liquid
vaporized over each theoretical stage is equal to moles of vapour condensed on
that stage. This implies that, molar flow rates of liquid and vapour in enriching
section (L and V) and also in stripping section (L and V) remain constant. To use
Process Engineering Channel

this method following information must be specified.

1. Feed flow rate, conditions and compositions
2. One product flow {D or W)
3. Product compositions or distribution of key and non-key components
4. Reflux ratio
5. Column pressure
@ProcessEng

Stepwise Lewis-Matheson method is as given below:

(i) Assuming that total condenser is used. L = RD and V = {R + \)D. Deter-
mine the dew point temperature of overhead vapour by using equation

X 'V' ' ^' = 1 (For non-ideal system) (8.28)

Yi Pvi
 Introduction to Process Engineering and Design

yM p,
or = 1 (For ideal vapour - liquid equilibrium) (8.29)
Pvi
where, yNi=xDi = x0l
yNi = Mole fraction of component i in vapour phase leaving the yvth
stage
xDi = Mole fraction of component i in distillate
xoj = Mole fraction of component i in reflux
pt = Operating pressure at top of distillation column, kPa a
pvi = Vapour pressure of component i at dew point temperature of
overhead vapour, kPa a
0, = Fugacity coefficient of component i in vapour phase
y, = Activity coefficient of component / in liquid phase
Same calculations (dew point temperature calculation) also give the value
of xNi

p,
x
Ni = (For ideal VLB) (8.30)
Pvi
where xNi = mole fraction of component i in liquid phase leaving the M11
tray.
Composition of vapour leaving the (N ~ l)th tray can be determined by a
material balance around the top section as shown in Fig. (8.8)
Vy(N-i)i = LxNi+ Dxoi (8.31)

Vv

L, Xffi y
y(N-\)i

*-D, xDl

;V
Process Engineering Channel

Ky(N-2)i
L. Xm;
Ky(N-i)i L,X(N-\)i

Fig. 8.8 Material Balance of Top Tray Fig. 8.9 Material Balance for (N-I)th Tray
@ProcessEng

By using above equation y(N_ are determined. After finding y(A,_ 1)(-, i.e.
th
composition of vapour leaving the (N - l) tray, find the dew point of this
vapour.

_ Pt
X = 1 (for ideal VLE) (8.32)
Pvi
 Process Design of Distillation Columns 421

Same calculations also give the values of x(N_ l);-, composition of liquid
,h
phase leaving the (A^ - 1 ) tray.
Material balance around (N- 1 )th tray gives composition of vapour leaving
the (A' - 2)th tray.

Vy(N-2)i - ty(N-\)i + LX{N-I)/ _

Lxm (8.33)
These calculations (i.e. dew point temperature calculations and material
balance calculations) are repeated upto the feed tray.
(ii) Feed Tray Identification:
To identify the feed tray following conditions must be satisfied.
If feed is liquid then mole fraction ratio or molar ratio of light key to
heavy key in the feed should lie in between the same ratios of the liquid
leaving the feed tray and of the liquid leaving the tray, next above the feed
tray.

/ \ / S / \
X X X
LK LK LK
< <
X
HK Feed tray kXHK ) Feed \XHK /T
/ ray above the feed tray

X LK X LK LK
or < < (8.34)
yXHK Nr. \XHK Feed v XHK A^+l

If the feed is a mixture of liquid and vapour then also the above condition
is valid. However, the difference is only liquid phase molar ratio is to be
considered for satisfying this condition.
If feed is vapour then condition is

x LK yLK ! KLK 'LK

< <
X l
X HK Tray beneath feed tray yHK /^HK Feed HK )N

l
z.x { yLK/KLK XLK
< <
or XL Xt (8.35)
NF-l V y'HK I KHk Feed Nr
Process Engineering Channel

(iii) For Stripping Section:

molar flow rate of liquid, L_= L + qF
molar flow rate of vapour, V = I - W
where, W = Molar flow rate of residue
Calculate the bubble point temperature of residue
@ProcessEng

X = 1 (For non-ideal VLB) (8.28)

Qi Pi

or I "V' Pvi = 1 (For ideal VLB) (8.30)

P,
 Introduction to Process Engineering and Design

Same calculations also give the values of yWi composition of vapour leav-
ing the reboiler.
l x
, 2\ V,yu
■^wi Pvi
ywi - (8.36)
P,
The material balance around the
reboiler gives
Lxu = Vywi + (8.37)
Calculate the bubble point tempera-
L,x\
ture of liquid leaving the Is' tray

XA"/7- = 1 (For ideal VLE) L,xVx^ IV, xwi

P,
(8 38) Fig. 8.10 Material Balance Around Reboiler

Same calculations also give y^, composition of vapour leaving the first
tray. Then material balance around lsl tray gives Xjj-
lx2i = Lxy + Vyu - Vywi (8.39)
nd
X2i is the composition of liquid leaving the 2 tray. These iterative calcula-
tions are repealed from bottom to feed tray. For feed tray xLK lxHK ratios,
one obtained from enriching section calculations and other obtained from
stripping section calculations, must be very close.
(iv) Normally, in the first trial calculations, it happens that on getting close val-
ues of the ratios xLK /xHK, one from enriching section and other from strip-
ping section, mole fractions of the components of feed, one obtained from
top section and other from bottom section do not match. If they are differ-
ent then it is called "mismatch".
If composition of liquid phase, leaving the feed tray, obtained from top section
calculations and the same from bottom section calculations are different, then to
match them one has to change product distribution and product rates. In other
words one has to change xDj, xWj, D and W. For the new values, entire calculations
must be repeated until the entire composition of liquid leaving the feed tray cal-
culated from top and bottom closely match.
Process Engineering Channel

In the first trial calculations, if composition of liquid leaving the feed tray
from top to down calculations and the same from bottom to up calculations are
not matching, then Smith suggests the following method to make the change in
product composition for 2nd trial calculations12.
Change in moles of component i in distillate for 2nd trial calculations, Ar/,- is
calculated by following equation
@ProcessEng

( XFB X
FD )/
Ad: = / \ (8.40)
XV-7) XIB
+
d //
where, xFBi = Mole fraction of component i in the liquid from feed tray as found
from the bottom to up calculations
 Process Design of Distillation Columns 423 |

xFDi = Mole fraction of component i in the liquid from feed tray as found
from the top to down calculations
d,b = Moles of component i in top and bottom products in last iteration
Then corresponding changes required in bottom product for component i is
Ahi = - Adj. For new distribution, entire calculation is repeated. This calculation
is continued until compositions of liquid, leaving the feed tray, obtained from
top-down calculations and bottom-up calculations are approximately same.
For more exact calculations, enthalpy balance should be done for each tray to
find the variation in liquid rate and vapour rate on each tray. But these calcula-
tions require detailed and exact enthalpy data. Also, if one considers it, then
calculations become more laborious and complicated. Use of computer is then
essential.

Example 8.10
A saturated liquid, consisting of phenol and cresols with some xylenols, is fractioned to
give a top product of 95.3 mole% phenol. Metacresol is heavy key and phenol is light
key component. Total condenser is used. The composition of the top product and of the
phenols in the bottoms are given.
(a) Complete the material balance over the still for a feed rate of 100 kmol/h.
(b) Calculate the minimum reflux ratio by Underwood's method.
(c) For R = 3Rm, calculate the composition of vapour entering to the top most tray by
Lewis-Matheson method.

Table 8.25 Distillation Column Data and Relative Volatilities

Component oc av Feed, mole % Top product, mole % Bottom product, mole %

Phenol 1.98 35 95.30 5.24

o-Cresol 1.59 15 4.55 ?
m-Cresol 1.00 30 0.15 ?
Xylenols 0.59 20 — 7

100 100.00

Solution:
Process Engineering Channel

(a) Overall material balance

F = D+W
100 = D+ W (1)
Phenol balance:
F x 0.35 =Dx 0.953 + Wx 0.0524 (2)
From Eq. (1) and (2), D = 33 kmol/h, W =61 kmol/h.
@ProcessEng

Component balance gives the composition of residue

o-Cresol balance:
F x 0.15 = 0.0455 xD + xWnxW
100 x 0.15 = 0.0455 x 33 + x 67
xWo = 0.2015
 Introduction to Process Engineering and Design

Similarly, xWm = 0.447, xWx = 0.2985

where, xWm = mole fraction of m-cresol in Residue
xWx = mole fraction of xylenol in Residue
(b) Rni by Underwood's method:

+ l (B.14)

1.98x0.953 1.59x0.0455 1x0.0015

+ + = Rm + I (3)
l.OS-'O 1.59-i3 1-13
where 0 is determined by following equation

_ OC - X:p
1.-^=1-1 (8.15)
oc,. -l3

1.98x0.35 1.59x0.15 1x0.3 0.59x0.2

+ + + = l-|=0 (4)
1.98-i3 1.59 -13 1--0 0.59-13

He -HF
Here q = and for saturated liquid HF = HL
hg-hl
By trial and error calculations, or by Mathcad, determine i3.
Also i3 e {1,... 1.98}.
i3 = 1.22
On substituting this value of i3 in Eq. (3) gives
Rm = 1.67
(c) R = 3 Rm = 3 x 1.67 = 5.01
L = RD,V=(R+ \)D
L = 5.01 x 33 = 165.33 kmol/h
V = (5.01 + 1) x 33 = 198.33 kmol/h
Refer Fig. 8.8.
Component balance around top segment

tytv-i)/ = Lxm + DxDi

Composition of vapour entering to top most tray

L D
Process Engineering Channel

y{N- I),- = —XNi + —Xf), (5)

At dew point of over head vapour

_ Vv. P,
=^,= 1 (6)
Pvi
But here operating pressure p, is not specified. So xNi cannot be determined by
@ProcessEng

Eq. (6). xNi can be determined based on the data of average relative volatility, o=avj.
=X
NP + xNO + XNm + XNx = '
where, xNi = Mole fraction of component i in the liquid leaving the A"1 tray
xNp = Mole fraction of phenol in the same
xNo = Mole fraction of o-cresol in the same
xNm = Mole fraction of m-cresol in the same
 Process Design of Distillation Columns

xNx = Mole fraction of xylenols in the same

Sv,. AL N,
+ +1+
l K l
N.. N
''n N..

Average relative volatility of phenol

yNlJxNP
yN/x,
,n

X N, y Np

N.. yN.

yND X nl.
■yN,
i
w.„

| | yy,,. | yy. y",,, v y",,.

^,v, =

Vn, y*..

-av,- X\Nm

From Eq. (7) and (8):

yND avp 0.953/1.98

X
NP -
ym (0.953/1.98) + (0.0455/1.59) + (0.0015/1)

xNp = 0.9411
Since total condenser is used, yNi = xDi
Similarly

0.0455
1.59 j
X
No = = 0.055 95
( 0.953 ^ ' 0.0455 W 0.00 IS")
Process Engineering Channel

+
I 1.98 J 1.59
xNm = 0.002 95
On substituting the values of xNi in Eq. (5)

165.33 .. 33
y{N-1)/ - X XNi + x xDi
198.33 198.33
@ProcessEng

165.33 33
y{N-\)p= x 0.9411 + x 0.953
198.33 198.33
= 0.8336x0.9411 +0.1664x0.953
=
y(N-1)P 0.943
y{N_ i)o = 0.8336 x 0.055 95 + 0.1664 x 0.0455 = 0.0542
y(N_ l)m = 0.8336 x 0.002 95 + 0.1664 x 0.0015 = 0.0027
 Introduction to Process Engineering and Design

Example 8.11
Find the number of theoretical stages required for the desired separation by Lewis-
Matheson method for the following case.

Table 8.26 Distillation Column Details

Component Feed, mole % Distillate, mole % Residue, mole %

n-Butane 37 95.0 16.3
i-Pentane 32 5.0 41.6
«-Pentane 21 — 28.5
n-Hexane 10 — 13.6
Total 100 100.0 100.0

1. F = 4750 mol/h, D = 1250 mol/h, W = 3500 mol/h and <? = 1

2. /i-Butane is light key component and /-Pentane is heavy key component.
3. Operating pressure p, = 2 atm a
4. Reflux ratio R = 3
5. Vapour pressures of components

In p.. = A , p.. in torr and 7 in K

(T + C)

Table 8.27 Antoine Constants9

Component A B C

n - Butane 15.6782 2154.9 - 34.42

i - Pentane 15.6338 2348.67 - 40.05
n - Pentane 15.8333 2477.07 - 39.94
n - Hexane 15.8366 2697.55 - 48.78

Solution:
Lewis-Matheson method
Molar flow rates of liquid and vapour in enriching section
L = RD, V=(R+ l)D
Process Engineering Channel

L = 3 x 1250 = 3750 mol/h, V = (3 + I) x 1250 = 5000 mol/h

For total condenser,
yNi=xDi = xoi
To find the dew point of over head vapour

^ P, = 1

Pvi
@ProcessEng

For T = 295 K (i.e. t = 220C), pvB = 1650 torr, pvjp = 615 torr

0.95 x (2x760) 0.05 x (2x760)

+ =
1650 615
or 0.875 15 + 0.1236 s 1
Hence dew point temperature of over head vapour, tDp = 220C.
 Process Design of Distillation Columns

The same calculation also gives

xNB = 0.875 15
xNlP = 0.1236
Material balance around the top segment, shown in Fig. 8.8.
=
tyw- 1)/ ^XNi + Dxdi

- 1 x ^ D
y'tN- 1)1 - y Ni + y x
Di

_ 3750 w , 1250
1)8 DS
" 5000 ^ 5000
y(N_ l)fi = 0.75 x 0.875 15 + 0.25 x 0.95 = 0.8939
y(N_ X)ip = 0.75 x 0.1236 + 0.25 x 0.05 = 0.1052
Find the dew point temperature of vapour leaving the {N - I)"1 tray by trial and error
calculations.
At t = 240C or 7 = 297 K
pvlj = 1757.3 torr, pvjp = 660.65 torr

v y{N-i) Pr 0.891 Ix (2x760) 0.1050 x (2x760)

+
~ 1757.3 660.65 ~

Dew point temperature of vapour leaving the {N - l)lh tray is 240C.

The same calculations also give
X
(N-\)B = ^ x(N-i)iP = 0-24
Here lx{N _i)(- = 1.01. To make this total = 1.000 normalized values of x(N _ l)(- are
determined as follows.

0.77 _ n -7,0/l
X(\j-\\ft
(N 1)3
— — 0.7624
0.77+0.24

0 24
x
(N-\)iP
(N D.P = —
0 77 +0 24 = 0.2376

Check whether the (N - l)lh tray is feed tray or not.

0.7624 ^ 37(molesof nQ in feed)

= = J.Z < (= 1.1 jo 25)
Process Engineering Channel

x
(N-i)p 0.2376 32(moles of iC5 in feed)

Hence (N - I ),h tray is not feed tray.

Component balance around (N- l),h tray
Refer Fig. 8.9.
=
Vy'w- 2)i LxfN_!),•+ tyiN- l)(_
_ L L
@ProcessEng

y(N- 2)i - '^'X(N -l)i + y(N -\)i~ ^XNi

y(N-2)B = 0-75 X 0-7624 + 0-8911 - O-75 X 0-875 15

y<N-2)B = ^•8^65,y)/v_2),/, = l-y(N-2)B ^ 0.1935

 Introduction to Process Engineering and Design

Find the dew point temperature of vapour leaving the (N - 2)th tray.
At, T = 301 K or / = 28° C, pvB = 1987.6 torr, pvlP = 760 torr

y(N-2)i Pi 0.8065 x (2 x 760) 0.1935 x (2 x 760)

Pvi 1987.6 760

= 0.6168 + 0.387= I
The same calculations also give

^(N-2)B = 0.6168 and _ 2ylp — 0.387

Normalized values of x{N_2)j
X =
(N-2)B 0.6182, x(N _ 2)ip = 0.3818
lh
Check whether (A - 2) tray is feed tray or not.

X
(N -2) B 0 6182 37
— = ———— = 1.62 <1 —(=1.156)
x
(N-2)iP 0.3818 32
(N - 2)th tray is not the feed tray.
Component balance around (N - 2)lh tray
=
Vy'fN- 3)i Lx(N_ 2)i + tyfW-2)i~ ^(N- I)i
L X
, L
y'tN -3)i - y (N - 2)1 + y(N -2)i y X
(N - I )i

y(N-3)B = 0-75 x
o-6182 + 0-8065 - 0-75 x 0-7624 = 0-6984
y{N-3)iP = 0.3016
Find the dew point of vapour, leaving the (A - 3)lh tray.
At T = 305 K or r = 320C, pvB = 2239.9 torr, pvip = 870.63 torr.

v y(N-3)iP, _ 0.6984x1520 0.3016x1520

+
^ ~ 2239.9 870.63
Dew point temperature of vapour leaving the (N - 3)th tray, rDp = 320C
The same calculations also give
X
(N- 3)B = O-4^ and x(A,_ 3)(7, = 0.53
Check (A - 3)"1 tray is feed tray or not.

X<N
-y"S 0 47
=0.887 <1.156 f= 37 ^
Process Engineering Channel

-
X
(N-3) if 0.53 v 327

(A - 3),h tray or 4lh tray from the top is the feed tray.
Molar flow rate of liquid and vapour in stripping or exhausting section:
L =L + Fq = 3750 + 4750 = 8500 kmol/h
V = L-W= 8500-3500 = 5000 kmol/h
Correct mole fraction of liquid leaving the feed tray
@ProcessEng

x
BF L =XBL + XBF

xBF = 0.47 x + 0.37 x = 0.414

8500 8500
(where xB is mole fraction of n-Butane in feed)
 Process Design of Distillation Columns

n „ ^ 3750 A 4750 ,.
X:pF = 0.53 x + 0.32 x =n
0.413
8500 8500

0.21x4750
r = =0.1173
8500

0.1x4750
=
X„HF
nHF ~ 0-056
8500
Composition of the liquid, leaving the feed tray obtained from top to down calculations.
XgF = 0.412, Xjpy = 0.413, xnPF = 0.1173, xnHF = 0.056
X
BF
= 1 < 1.156
XjPF
Bottom to up calculations:
Find the bubble point of residue via trial and error calculations:
X
v wi Pvi = 0- '63 x pvl; ^ 0.416 pvip | 0.285 pvllp | 0-136 pvnH
p, 1520 1520 1520 1520
At t = 480C or 7= 321K

x
„ wi Ppvi 0.163x3494+0.416x1442.4+0.285x1118.8 + 0.136x375
p, 1520
= 1.01 = I
Hence bubble point temperature, rBp = 480C
The same calculations also give the vapour composition, leaving the reboiler
x
wB PvB a -ina
y wB = = 0-375
P,
yWiP = 0.395, ywnp = 0.2098, ywnH = 0.033
Component balance around reboiler gives (Ref. Fig. 8.10)
Lx\i = yyWi + Wx
wi

V W _ 5000 3500
XU + Xwi +
~ L^ L 8500 ^ 8500 ^
= 0.5882 ywj + 0.4118 xwi
Process Engineering Channel

Composition of liquid, leaving the 1SI tray

x]B = 0.5882 x 0.375 + 0.4118 x 0.163 = 0.2877
xUp = 0.5882 x 0.395 + 0.4118 x 0.416 = 0.4036
xinp = 0.5882 x 0.2098 + 0.4118 x 0.285 = 0.24
xinH = 0.5882 x 0.033 + 0.4118 x 0.136 = 0.075
@ProcessEng

— = Q-2877 = 0.7128, — = 1.0036

x
-^1 IP 0.4036 iPF
x X
\B BF
Hence < and 1SI tray is not the feed tray.
x x
\ iP iPF
Find the bubble point of liquid leaving the 1st tray by trial and error calculations.
 Introduction to Process Engineering and Design

At t = 410C or T = 314 K
pvij- 2894.5 torr, pvtp = 1164.97 torr, pvnl, = 893.26 lorr
pvnH = 288.76 torr, (by using Antoine equations)

v x,pvi _ 0.2877x2894.5 i 0.4036x1164.97 0.24x893.26

+ +
p, ~ 1520 1520 1520

0.075 x 288.76
+ = 1.012= 1
1520
Bubble point of liquid leaving the lsltray, rBI> = 410C. Same calculations also give the
composition of vapour, leaving the 1st tray.

xiBpvB 0.2877x2894.5
ylB = = = 0.548
p, 1520

yup = 0-309, y[np = 0.141, ylnW = 0.014

Normalised values of y,,-

0.548 0.548
= =0.5415
Zy,, 1.012

0.309 n ,n-
yUp - = 0.305
" 1.012

0.141 ni,n
yUtp = =0.139
1.012

O.OM nn.-io
yulnH
.H = = 0.0138
1.012
Component balance around the lsl tray gives

^x2i = Vyu + Lxu - yywi

V , V
x2i= -yu + xu- -ywi
L L

x7lt = x 0.5415 + 0.2877 - x 0.375 = 0.3856

Process Engineering Channel

8500 8500

x2ip = x 0.305 + 0.4036 - x 0.395 = 0.3506

8500 8500

x = ^00 x 0.139 + 0.24 - -^2 x 0.2098 = 0.1984

8500 8500
@ProcessEng

x7nH = x 0.0138 + 0.075 - x 0.033 = 0.0637

8500 8500

^ 03856^,^^ 025)
x^p 0.3506 Xjpp
 Process Design of Distillation Columns 431

X
BF
2nd tray from bottom can be called the feed tray. Ideally values of this ratio

obtained from bottom to up calculations should be same as that obtained from top
to down calculation. Here composition of liquid leaving the feed tray obtained from top
to down calculations and the same obtained from bottom to up calculations are not
matching.

Table 8.28 Summary of First Trial Calculations of Feed Tray Liquid

Component Composition based on Composition based on

top-down calculation bottom-up calculation

n-Butane 0.412 0.3856

/-Pentane 0.413 0.3506
n-Pentane 0.1173 0.1984
rt-Hexane 0.056 0.0637

To match this composition and to get the exact value of number of theoretical stages
required for the desired separation of key components, second trial calculations are
required. Based on lsl trial calculations number of theoretical stages required for the
desired separation of key components is 6. (Reboiler, lsl, 2nd = TV - 3 = Feed tray, N -2,
N- 1, AO
How to start the second trial calculations?
To start the second trial calculations, product compostion xDi and xWj (hence, D ans W
also) must be changed. Based on the Smith's suggestion following equation can be used
to make the change in product composition for the 2nd trial calculations.
Change in moles of component in distillate.

{xFB xFD )i
M= (8.40)
xFD X FB
d //

For n-Butane or for nC,

0.3856-0.414
MnC4 = = -27.72 mol/h
0.412 0.3856
Process Engineering Channel

+
1250x0.95 0.163x3500

nC4 in distillate for the 2nd trial calculation

= 1250 x 0.95 - 27.72 = 1159.78 mol/h
nC4 in residue = 0.163 x 3500 + 27.72 = 598.22 mol/h
For /.vo-Penlane or iC5:
@ProcessEng

0.3506-0.413
Mic5 = = -9.1 mol/h
0.413 0.3506
+
1250x0.05 3500x0.416

iC5 in distillate = 1250 x 0.05 - 9.1 = 53.4 mol/h

iC5 in residue = 3500 x 0.416 + 9.1 = 1465.1 mol/h
 432 Introduction to Process Engineering and Design

For n-Pentane or nC5:

0.1984-0.1173
Ad
nC5 = ,
0.1173 0.1984 ")
+
cl nO 3500 x 0.285 J
5 /
In Is' trial calculation dnCi = 0. But to use above equation one cannot put dnCi = 0. Let
dnC5 = 1 mol/h (negligible value)

Mnc5 = 0.6913

nCi in distillate = 1 + 0.6913 = 1.7 mol/h

nr in residue = 3500 x 0.285 - 1.7 = 995.8 mol/h
For n-Hexane or n
Q."
0.0637 - 0.056
^c6 =
0.056 0.0637
+
d nC. 3500x0.136
6 y
Let dnC(i = 1 mol/h (negligible)
dnC(, = 0.137 mol/h
nCh in distillate = 1.137 mol/h
in residue = 3500 x 0.137 - 1.137 = 474.86 mol/h
*-6

Table 8.29 Product Composition for Second Trial Calculations

D W
Component mol/h mole fraction mol/h mole fraction

1159.78 0.954 598.22 0.169

ic5 53.4 0.044 1465.1 0.415
nc5 1.7 0.001 995.8 0.282
nC6 1.137 0.001 474.86 0.134
Total 1216.02 LOO 3533.98 1.00

Based on this new product distibution one can start the second trial calculations. These
trial calculations are repeated until the composition of liquid leaving the feed tray ob-
Process Engineering Channel

tained from top-down calculations match with the same obtained from bottom-up cal-
culations. Results obtained at the end of 1SI trial calculations are matching with the same
given by FUG method.

(II) Thiele Geddes Method1:

Original method of Thiele and Geddes was developed for manual calculation in
1933. There after computer programs are developed for this method to reduce the
@ProcessEng

labour of calculations. This method is a rating method in which distribution of

components between distillate and bottoms is predicted for a specified number of
stages.
In this method following variables are to be specified as input data.
1. Number of equilibrium stages above and below the feed.
2. Column pressure
 Process Design of Distillation Columns

3. Temperatures (stage wise)

4. Reflux flow rate
5. Distillate rate
6. Feed flow rate, feed condition and feed composition
7. Liquid and vapour flow rates, leaving each stage
Calculation procedure is as follows.
Material balance for any component around the condenser is
G
\ y\=Lo x0 + d
Zd
G\
G
\ >'i hxo , y.
+ 1
Dz D Dz D, zD
Lo-XQ
4
For a total condenser, y] = x0 = zD = xD and =R
D

_ L.
O + 1 =/? + 1 = + 1
Dzd D
Fig. 8.11 Material Balance Around
L. Overhead Condenser
where A0 = — = R (for total condenser)

For a partial condenser, zD = yD = K0 x0

where, K0 = equilibrium constant for partial condenser

L x
o o R_
+ 1= +1= + 1 =A0+l
Dz D Dz D DK„ K„

_R^
where = (for partial condenser)
Kn

Component balance upto tray 1 gives

G2 yz - xi + Dzd D, zD

G2 yi A x\
+ 1 (8.41)
Dzd Dzd

for Tray 1, absorption factor

Process Engineering Channel

L\ hx\ T-i, X| (72, yz

A, = (8.42)
K\GX Gxyx
Fig. 8.12 Material Balance Around
L| X| = G| yx A| Top Section up to First Tray

Form Eq. (8.41) and Eq. (8.42)

@ProcessEng

G2 y2 G\ yj A,
+ 1 = (A0 + 1) A, + 1 = A, A0 + A, + 1
Dzd DZ./)
Similarly for the vapour coming from any nlh tray

Gnyn Aj -i 4-1 -1
- A() A, A2 ... A n- I
Dz D Dzd
+ A, A2... An _,+ ...+ A,, _ j + 1 (8.43)
 434 Introduction to Process Engineering and Design

For the vapour coming from feed tray

Gp yp
— Aq A^ A2 Ap
F- 11 + A,
i] A
^2 F- 1 + ... +A F-i + 1 (8.44)
Dz D

For stripping or exhausting section:

Component balance around reboiler
Lnxn = GN + ]yN+l + WxH N
~4r-
Cn+ UJVN+ 1
Ln xN GN + -[yN + x
+ 1
Wxw Wx,
Z-n, XN
LN Xn
= S... + 1 (8.45)
Wx.
ir,xw
where Sw is stripping factor of reboiler.
Fig. 8.13 Material Balance Around
For kettie type reboiler stripping factor
Reboiler

G/v + ] y/v +1 GN+1 Kb

S,., = (8.46)
Wx,

(Since for kettle type reboiler yiv+ 1 = xw)

where, Kb = equilibrium constant for kettle type reboiler
For thermosyphon reboiler yyv + 1 = -%
Stripping factor for thermosyphon reboiler

GN+l
S,.. = (8.47)
VF
Component balance around bottom section .Vn ^N-\txN-
up to the last tray.
x =
Ln- 1 n- 1 Gn yN + Wxw

L■N -l -1 GN JN
+ 1 (8.48) A
Wxw Wxw
Process Engineering Channel

th
Stripping factor for N tray

c _ gnkn Gn JN
■j,v -
L■N Ln xN
, ,, ^ . r »jih Fig. 8.14 Material Balance Around of
where, a.,v = bquilibnum
1 constant lor jv n - . rT
' Bottom Section up to Final Tray
tray
@ProcessEng

GN yN - LN X
N SN (8.49)
From the Eqs (8.44) and (8.48)

LN -\ XN -] X
LN N
^+1 (8.50)
Wxw Wxw
 Process Design of Distillation Columns 435 [

From Eqs (8.47) and (8.50)

L x
N
~1 N
~- ={Sw+l)SN+ l=SwSN+SN+ I (8.51)

For any mth tray of stripping section

=
+ i• Sm + 2 SN_] • SN • Sw + Sm + j • Sm +2 ■■■
Wxw

^N- i ^ + Sm + | • Sin + 2 SN_ j + .... + Sm +1 + 1 (8.52)

For the liquid leaving the feed tray

TjT =
Sf+ i ' SF+2 ■■■ SN- Sw + SF+ j • 5^+2 SN
Wxw
+ SF+ , ... SN _x + +5f+1 + 1 (8.53)
Absorption factor for feed tray

Zy/T Zy/T XF
AF= — = -^- (8.54)
KfGf GFyF
where, KF = Equilibrium constant for feed tray

Wxw GFyFIDzD LfXf (GFyF/DzD) /o ccx

—— = — =— AF (8.55)
Dzo LfXf/WXw Gf yF (LfXf/WXW)
Symbol z.D is mole fraction of distillate which can be liquid, vapour or liquid-
vaopour mixture.
In calculations, GFyF/DzD ratio is determined by Eq. (8.44). (LF xF)l{Wxw)
ratio is determined by Eq. (8.53).
Absorption factor for feed tray is determined by Eq. (8.54). The values are
substituted in Eq. (8.55) and the ratio WXwIDzd is determined.
Overall component balance
FZF=WXW + Dzd (8.56)

FZf _ Wxw ^ ^

Dzd Dzd
Process Engineering Channel

FZF
(8 57)
-
^ +1
Dzd
Equation (8.57) gives the value of Dzd, then Eq. (8.56) gives Wxw. Thus finally
one can get the product composition.
@ProcessEng

This product composition is correct, if all input data are correct. Normally in
the first trial calculations temperatures at the trays are assumed to calculate the
equilibrium constants; Ks. To verify whether assumed values of temperatures are
correct or not, find yn by following equation.

y„ = x ^ (8-58)
Dzd Gn
 Introduction to Process Engineering and Design

G,, yn
where, is determined by Eq. (8.43).
Dzd

For any tray n, yn's for all components must be determined by Eq. (8.58). Then
check whether = 1 or not.
If Eym- = 1, it means assumed value of temperature for tray n is correct. If
Eym- ^ 1, adjust the values of yni and find new dew point temperature. Same calcu-
lation should be done for all the trays.
Similarly in stripping section for each tray find

Lm xm Wxw
X
'"=1^
WXw
X
^—
Lm
(8 59)
-

and check whether Ex,,,, = 1 or not.

Lm X,„
Here is determined by Eq. (8.52).
Wxw
If Ex,,,,- ^ 1, then adjust the values of x, and find new bubble point.
For new temperatures, carry out the material balance and enthalpy balance
simultaneoulsy and find the new values of molar liquid flow rates and molar
vapour flow rates (new values of L's, G's, L's, G's). Then repeat the calculations.

Example 8.12
Find the product composition by Thiele - Geddes method based on the following data.

Table 8.30 Feed Composition

(i) Component mole %

n-Butane 37
/-Pentane 32
«-Pentane 21
n-Hexane 10

n-Butane is light key component and /-Pentane is heavy key component.

(ii) Feed flow rate /*" = 4750 mol/h. Feed is saturated liquid at its bubble point.
(iii) Reflux ratio, R = 3
Process Engineering Channel

(iv) D = 1250 mol/h, W = 3500 mol/h

(v) Operating pressure, pr = 2 atm a
(vi) Assume constant molar overflow. Total condenser is used.

Table 8.31 Equilibrium Constants Data (K^s)

Tray number Temperature Kr4 K k

„c5 K
@ProcessEng

ic5 C6
0
1 22 C 1.086 0.4046 0.3000 0.0870
2 240C 1.156 0.4346 0.3230 0.0950
3 280C 1.308 0.5000 0.3747 0.1125
4 = feed 320C 1.474 0.5730 0.4324 0.1330
5 4I0C 1.904 0.7660 0.5877 0.1900
Reboiler 480C 2.300 0.9500 0.7360 0.2500

(Read from Fig. 6.20)

 Process Design of Distillation Columns 437

Solution:
Molar flow rates of liquid and vapour in enriching section.
L = R D = 3 x 1250 = 3750 mol/h
G = (R + l)D = 4x 1250 = 5000 mol/h

Wxw Gp y p / Dxp)
xAp
Dx d Lp Xp/Wxyy

Gp yp
— Aq A | A-, ... Ap_ | + ... + Ap_ | + 1 (8.44)
uxD
Here 4th tray is feed tray.

Gp yp
— =A0 A, Aj A3+A, Aj A, + A2 A3 + A, + 1
Dxd
for n-Butane
Aq=R = 3

U L 3750
A|
" KX1 G ~K G~ 1.086x5000 " 0'6906
4

A2 = = = () 6488
Kc G 1.156x5000 '

^ = 3750 = 0 5734

1.308x5000

Gp yp
' = 3 x 0.6906 x 0.6488 x 0.5734 + 0.6906 x 0.6488 x 0.5734
Dxd
+ 0.6488 x 0.5734 + 0.5734 + 1 = 2.973

af=
KpGp

L =L + Fq = 3750 + 4750 x 1 = 8500 mol/h

Kp = Kc^ at feed tray temperature (equilibrium constant for n-Butane)
Process Engineering Channel

Kp = 1.474

8500 .
Af = = 1.1533
1.474x5000

—— = Sp+l-Sp + 2- --SN-Sw + Sp+l...SN+...Sp+l + \ (8.53)

G = G + F(q - l)or G = L - W= 8500 - 3500 = G = 5000 mol/h

@ProcessEng

L-J F -X L'
—^ =55^+55 + 1

K5G 1.904X5000
5. = = =1.12
I 8500
 Introduction to Process Engineering and Design

Kw G 2.3 x 5000
Sw = —^ = = 1.353
L 8500

Lf xF
1.12 x 1.353 + 1.12 + 1 = 3.6354

Wxw (Gf yF /Dxd) 7 973

—— = —xAp= x 1.1533 = 0.943 16 (8.55)
Dxd (Lp xF / Wxw) 3.6354

Fzp 4750 x 0.37

=isr"==904-4546 moVh <8 57)
-
—— + [
Dzd

Wxw = 853.05 mol/h

= 0.723 56, = 0.244
For /,vo-Pentane;

3750
A0=R = 3, A|=-^=
K^G K^x 5000

A,1 = — = a75 = 1.8537

KiC^ at 22° C 0.4046

L 0.75
A2 = —= 1.7257
K2G 0.4346

L 0.75
A3 -
K3G 0.5

6/ } F
=3x1 .8537 x 1.7257 x 1.5 + 1.8537 x 1.7257 x 1.5 + 1.7257 x 1.5 + 1.5 +
Dxq
= 24.282
Absorption factor for feed tray
Process Engineering Channel

A = 8500 = 2967
F
KpG 0.573 x 5000

Lf Xp
—^ =S5SH,+ S5+1
Wxw

K.G 0.766x5000
@ProcessEng

5* = —^- = = 0.45
L 8500

Kw G 0.95 x 5000
V= -^ = = 0.56
lV
r 8500
 Process Design of Distillation Columns 439

LF Xp
= 0.45 x 0.56 + 0.45 + 1 = 1.702
Wxiw

= 24.282
x 2.967 = 42.33
DXD ~ 1.702

4750 x 0.32
Dxd = = 35.08 mol/h
(42.33 +1)
Wxw = 1485 mol/h
xD = 0.028, ^ = 0.4243
For /-pentane, similarly one can calculate, xD = 0.005 58, xw = 0.283 and for n-hexane
xD ~ 0 and xw = 0.1357

Table 8.32 Resulting Product Compositions

Component Dnor
«-Butane 0.723 56 0.9556 0.2440 0.2244
/-Pentane 0.028 00 0.0370 0.4243 0.3900
n-Pentane 0.005 58 0.0070 0.2830 0.2600
/j-Hexane 0.1357 0.1248
Total 0.757 14 1.0000 1.0870 1.0000

•%nor= Normalized values ofxDi

xwnor = Normalized values of xwi

(III) Equation-Tearing Procedures Using Tridiagonal Matrix Algorithm14:

This method require the help of a computer. This method is more general and
flexible, compared to Lewis - Matheson method and Thiele - Geddes method.
Consider a general continuous flow steady state, multicomponent multistage
distillation operation. Assume that phase equilibrium between an existing vapour
phase and existing liquid phase is achieved at each stage, that no chemical reaction
takes place, and that neither of the existing phase entrains the other phase. Consider
the general equilibrium stage j as shown in Fig. 8.15.
Here Fj represent molar flow rate of feed to a stage j at temperature TFj and
Process Engineering Channel

pressure pFj and with overall composition in mole fractions Zjj- If stage j is not
feed stage then in calculation Fj = 0. Heat is transferred from stage j (+ ve ) or to
stage j (- ve) at rate 0y. If there is no external heat exchanger, attached with stage
j, then (pj = 0. Equilibrium vapour and liquid phases leave the stage j at tempera-
ture Tj and pressure pj and with mole fraction and respectively. The vapour
may be partially withdrawn from the column as side stream at a molar flow rale
@ProcessEng

W: and the remainder Vj is sent to adjacent stage j - 1 above. Similarly existing

liquid may be split into a side stream at a molar flow rate of Up with the remainder
Lp sent to adjacent stage / as follows:
For each stage j following independent equations can be written.
1. Component material balance equations (M)
V, A-,, H + Vj+i yF , + | + Fj Hj - (Lj + Uj) Xij - (Vj + Wj) y^ = 0 (8.60)
 Introduction to Process Engineering and Design

V,
Liquid from
Vapour stage above
side stream Lh
IV. ^

H,i-j-l
7, r,_
P; p..
/"I

Heat transfer
Feed
Stagej
z7 2; '
(+) If from stage
// (-) If to stage
^,/+i '.7
"v/+l //
,/+l
/+! p,

Liquid side stream

Fy+,
Vj
Vapour from
stage below
L
j
Fig. 8.15 General Equilibrium Stage

2. Phase equilibrium equation (E)

(8.61)
Vij - V x'j ~ o
3. Mole fraction summation equation (S)
1.0 = 0
Lx-. - 1.0 = 0 (8.62)
4. Energy balance or enthalpy balance equation (H)
H
h-i lh + ^+i ^7+i + Fj "FJ - (Fj + V.) HLj -{Vj+ Wp Hvj -0-0
(8.63)
These equations are known as MESH equations. For evaluating different vari-
Process Engineering Channel

ables namely; flows, compositions, temperatures and pressures, number of MESH

equations are necessary. For this pupose, degree of freedom dictates that for any
stage j total 2C + 3 MESH (= C No. of material balance equations -I- C No. of
phase equilibrium equation + 2 No. of mole fraction summation equations + 1
No. of energy balance equations) equations (where, C = number of components)
can be written. For total N number of equilibrium stages, N (2C + 3) MESH
equations can be written. Total number of variables are N (3C + 10) + 1. Differ-
@ProcessEng

ence between total number of variables and number of equations is V (C + 7) + 1.

Hence N (C + 1) + 1 variables must be specified.
On combining MESH equations to eliminate y/s and L^'s, following equations
are obtained.
Aj xu _ , + Bu xy + Cu Xi j + l = Djj

where, Aj - Vj + Z (F,()-lVm-f/J-y(.2<y<iV
m=\
 Process Design of Distillation Columns

+ ^ (Fm-Wm-UJ-V, +Ui+(Vi +W:)K/i l<j<N

m=l

C(;=y/+lXrJ+,
D =
ij " fj Zy \<J<N
Equation (8.63) is a general representation of total NC equations. Each set of
N equations is a tridiagonal matrix equation. For example, if ./V = 5, for each
component following equations can be written in tridiagonal matrix form.

C, 0 0 0 D
\
^2 C
2 0 0 *2 Di
0 C 0 — D, (8.64)
^3 3 *3
0 0 4 4 Q *4 D4
0 0 0 4 4 *5 lD5

Each set of above equations give the mole factions of one component in the
liquids, leaving all the trays (equilibrium stages). Substitution of values in the
phase equilibrium equations give the values of yrr Like that all unknown vari-
ables are determined. For solving such equations, a mathematical software (such
as Mathcad) is useful.

8.4.6 Step 6: Selection of Type of Tower

Criteria of selection between tray tower and packed tower are discussed in Sec.
8.3 of this chapter.
Selection of Tray Type: Different types of trays used in tray tower are (i) sieve
tray, (ii) bubble cap tray, (iii) valve tray, (iv) Linde trays and other modified sieve
trays.
Various factors that must be considered for the selection of tray type are
(a) cost (b) capacity (c) operating range, (d) efficiency and (e) pressure drop
(a) Cost: Bubble cap tray is the costliest type of tray. With mild steel as a
material of construction, the ratios of cost
Process Engineering Channel

Bubble cap: Valve: Sieve trays = 3: 1.5:1 (general guideline)

In other words, cost of bubble cap tray is three times the cost of sieve
tray and double the cost of valve tray with mild steel as material. With
different materials these ratios are somewhat different.
(b) Capacity: If tower diameter required for given flow rates is more it means
capacity of tray is less. The ranking for capacity is in order of modified
sieve tray, sieve tray, valve tray and bubble cap tray. In other words for the
@ProcessEng

given flow rates, tower diameter required is maximum with bubble cap
trays and minimum with modified sieve tray. However, the difference in the
values of tower diameters is not large.
(c) Operating range: It is an important factor for the selection of tray. Operat-
ing range of tray means range of liquid and vapour flow rates over which
 Introduction to Process Engineering and Design

tray works satisfactorily. Bubble cap tray provides the maximum operating
range while sieve tray provides the minimum operating range. Operating
process plants are designed and operated with some maximum capacity
and also for some minimum capacity. Hence, distillation columns are oper-
ated in the range of some maximum feed flow rate to minimum feed flow
rate. The ratio of maximum flow rate to minimum flow rate is called turn-
down ratio. Some process plants are frequently operated at very high turn-
down ratio to meet the product's demand and to avoid the shut down and
start-up conditions as during shut down and start-up periods, operating
plant provides very poor efficiency. For higher turndown ratio, bubble cap
trays are preferred. Valve trays also offer more flexibility or higher turn
down ratio than the sieve trays. However, in actual plant operation, valves
get stuck-up or fly-away if operating conditions are frequently changed. In
such a case, valve trays loose efficiency.
(d) Efficiency: This factor is not generally considered for the selection of tray
type. Efficiency of trays are almost same, if they are operated at design
flow rates, or with minimum turn down. However, bubble cap columns
give good efficiency over a wider range of turn down in general.
(e) Pressure drop: Pressure drop over the tray and for entire column is impor-
tant for vacuum distillation for which a packed tower is the first choice. But
for the low vacuum (upto 700 torr) operation, tray tower can be selected to
get other advantages. For example, to get the better vapour - liquid contact
in large diameter column or to facilitate the side draws. Among the trays,
sieve tray provides the lowest pressure drop, followed by valve tray, while
bubble cap provides the highest pressure drop.
Sieve trays and modified sieve trays are the cheapest and are satisfactory
for the majority of the applications. Nowadays, majority of chemical plants
are having automatic and precise control system and hence flow rates are
not much fluctuating. However, to meet the fluctuation in the demand of
product, some plants are intentionally operated with different flow rates or
capacities. To handle the higher turn down ratio, valve trays or bubble cap
trays are considered. Valve trays are cheaper than bubble cap trays but they
are not suitable for very low vapour rate. Bubble cap tray provides higher
Process Engineering Channel

efficiency even with low vapour flow rate.

8.4.7 Step 7: Tower Diameter and Pressure Drop

Determine the tower diameter and pressure drop. Method to find the tower diam-
eter and pressure drop for the packed tower type absorber is explained in Sec.
9.3.1 of Chapter 9. Same method and same Fig. 9.3 can also be used for the
distillation in packed tower.
@ProcessEng

8.4.7.1 Determining the Tower Diameter of Sieve Tray Tower

Flooding in sieve tray tower fixes the upper limit of vapour velocity through the
tower. Velocity of vapour at which flooding in sieve tray tower occurs is called
flooding velocity, vF. Tower diameter of sieve tray column is decided based on
 44
Process Design of Distillation Columns 3j

the value of vF. Actual velocity or design velocity through distillation column
should be in the range of 70 to 90% of flooding velocity. Ideally it should be in
between 80 to 85%.
Flooding is an inoperative condition. Flooding phenomena or flooding veloc-
ity are defined differently for different equipments. For example, in case of knock
back condenser, flooding velocity is the velocity of vapour at which entrainment
of liquid droplets in vapour just starts or the velocity of vapour at which % en-
trainment of liquid droplets in vapour becomes greater than zero. While in distil-
lation column entrainment of liquid droplets in vapour up to 10% is normally
accepted.
Flooding in tray tower of distillation column can occur or observed in either of
the following ways'6:
(i) Jet Flooding: In distillation operation froth of liquid-vapour mixture forms
on each tray from which nearly clear vapour is separated and rises upward
to meet the liquid on the next above tray. When froth of liquid-vapour
mixture touches the next above tray it is called jet flooding. Actually the
vapour flows through perforations of tray forms a free flowing jet after
leaving the orifice. Liquid droplets are entrained in these free flowing jets.
These free flowing jets combinedly form the froth. When this froth touches
the next tray above, it is called jet flooding.
(ii) Downcomer Flooding: In distillation column, liquid flows in downward
direction by gravitational force but it flows against the pressure. When liq-
uid flows from one tray to next below tray, it flows from lower pressure to
higher pressure. Hence, to compensate that, it elevates certain level inside
the downcomer. When the liquid level in downcomer on any tray rises above
the weir, it is called downcomer flooding.
Nowadays, it is possible to find tray or trays which restrict the capacity of
existing tower or which decide the maximum capacity of existing tower. To find
these trays of existing tower, one can intentionally operate the tower with maxi-
mum flow rates or even in flooding condition for a short period of time. During
that time photograph of each section of tower can be taken with y-rays. In these
photographs one can clearly see the froth zone above the trays and liquid level
inside the downcomers. Based on that one can find a tray or more than one tray
Process Engineering Channel

which decide the maximum capacity of tower. If these sieve trays, which restrict
the capacity of sieve tray tower, are replaced by modified or high capacity sieve
trays, then it is possible to increase the capacity of existing tower (may be up to
20%).
Flooding velocity through sieve tray tower can be determined by following
equation.
@ProcessEng

(8.65)

where, vF = Flooding vapour velocity based on net cross-sectional area, m/s

Cy= Flooding constant which can be obtained from Fig. 8.16.
<j= Surface tension of liquid, N/m
 Introduction to Process Engineering and Design

Plate spacing, m
90
Q 10-1 so
45
30
0.2

10-2
0.01 1.0

F,LV

Fig. 8.16 Flooding Velocity (Sieve Plates)9

(Reproduced with the permission of McGraw-Hill Education. USA)

pv = Density of vapour, kg/m3

Pi = Density of liquid kg/m3
.0.5
A_
Flv = liquid-vapour flow factor = (8.66)
IV Pl
Lw = mass flow rate of liquid, kg/s
Vw = mass flow rate of vapour, kg/s
Figure (8.16) gives flooding velocity with ± 10% error, subject to the following
restrictions:
1. System is non foaming.
2. Weir height is less than 15% of plate spacing.
3. Sieve plate perforations are 13 mm or less in diameter.
Process Engineering Channel

4. Value of Cyobtained from Fig. (8.16) is valid only ifAh/Aa >0.1. If Ah/Aa<
0.1 then Cf. Value obtained from Fig. 8.16. must be corrected by multiply-
ing it with following correction factor.
A,/A, Correction Factor
0.08 0.9
0.06 0.8
@ProcessEng

where, A, = Total area of all active holes

Aa = Active or bubbling area of tray
/4„ = Net area available for vapour-liquid disengagement
For a single pass tray An = Ac-Ad and Aa = Ac - 2Ad,
where, Ac = Total column cross-sectional area
Ad = Cross-sectional area of down comer. Down comer area
Ad ranges from 8 to 12 % of A(.
 Process Design of Distillation Columns

8.4.7.2 Selection of Liquid Flow Pattern

After finding the tower diameter, liquid flow pattern over sieve tray is decided.
Common liquid flow patterns of cross flow sieve tray are shown in Fig. (8.17). In
most of the cases single pass (cross flow; Fig. 8.17(a)) pattern is selected. Liquid
flow pattern depends on the liquid flow rate and tower diameter. Following table
can be used for the selection of liquid flow pattern.

Tray Tray Tray

Weir Weir
Downflow
Downflow Downflow Weir
T

Wer Ba
<Wcir

X
Downflow Downflow Downflow
Crossflow Reverse flow Double Pass
(a) (b) (c)
-Jx—
Tray
Intermediate
I weir
Tray Downflow
Downflow Weir Weir
ill1
vXr
Intermediate weirs

Double Pass (Cascade) Four Pass

(d) (d)
Fig. 8.17 Common Liquid Flow Patterns in Cross Flow Plates'4.
(Reproduced with the permission of McGraw-Hill Education. USA)
Process Engineering Channel

Table 8.33 Selection of Liquid Flow Pattern

Column Range of liquid flow rate, nrVs

diameter, m Reverse flow Cross flow Double pass Cascade
(single pass ) double pass

0.9 0- 1.90 x 10'3 1.90 x 10~3-0.0126

@ProcessEng

1.2 0 - 2.50 x 10"3 2.50 x lO"3-0.0190

1.8 0 - 3.15 x I0-3 3.15 x lO"3-0.0250 0.025 - 0.0440
2.4 0 - 3.15 x 10-3 3.15 x lO"3-0.0315 0.0315-0.050
3 0 - 3.15 x 10-3 3.15 x lO"3-0.0315 0.0315 -0.057 0.057 - 0.0880
3.66 0-3.15 x lO"3 3.15 x lO"3-0.0315 0.0315 -0.063 0.063 -0.1000
4.6 0 - 3.15 x I0"3 3.15 x 10"3-0.0315 0.0315 -0.070 0.070-0.1136
6 0 - 3.15 x lO"3 3.15 x I0"3-0.0315 0.0315 -0.070 0.070-0.1260
 Introduction to Process Engineering and Design

Tower diameter also depends on tray spacing. Value of flooding constant de-
pends on the value of tray spacing (Fig. 8.16). Tray spacing ranges from 0.15 m
to 1 m. At design stage, if the tray spacing is increased, required tower diameter
decreases, tray efficiency increases and hence actual number of trays required for
desired separation decreases but overall height for tower increases. Ideally one
should find the optimum tray spacing or the tray spacing for which total cost of
tower is minimum. If column diameter is less than 1 m, tray spacing is kept 0.2 to
0.3 m. For columns above 1 m diameter, tray spacing of 0.3 to 0.6 m is used. For
the first trial calculations one can start with tray spacing equal to 0.3 m but if
column diameter is calculated to be more than 1 m then for the second trial calcu-
lations, tray spacing can the taken equal to 0.4 to 0.5 m. Even with smaller tray
spacing of 0.15 to 0.3 m, larger spacing is needed between certain plates to ac-
commodate nozzles for feed, side streams, for manholes, etc.

8.4.7.3 Checking of Liquid Entrainment

As a rough guide, the % of liquid entrainment should be less than 10%

kg of liquid droplets entrained

% liquid entrainment = x 100 (8.67)
kg of gross liquid flow

or % liquid entrainment = lOO^P

where, = Fractional liquid entrainment

^ kg of liquid entrained Moles of liquid entrained

kg of gross liquid flow Moles of gross liquid flow

Value of ^ as a function of liquid-vapour factor (FLV) with % of flood as a

parameter is given by Fair17. The same is reproduced in Fig. (8.18). T* should be
less than 0.1, to get higher tray efficiency. Optimum value of \f/ can be greater
than 0.1.

Actual vapour velocity based on net area

% of flood = : x 100 (8.68)
Flooding velocity

= — x 100
Process Engineering Channel

v
/

8.4.7.4 Weir

The height of weir decides the height of liquid over the tray. In most cases, weirs
are straight and rectangular plates. With bubble cap trays, to compensate the
fluctuations in the flow rate, V-notch type weirs are used. A high weir provides
higher plate efficiency but at the expense of pressure drop. For a distillation column
@ProcessEng

operating above atmospheric pressure, weir height is kept in between 40 mm to

90 mm; while 40 mm to 50 mm is more common. For vacuum operation, to
control the tray pressure drop, weir height is reduced and it is kept in between 6
to 12 mm. In old designs, inlet weir was also used, but in recent designs inlet weir
is not recommended as it results in hydraulic jump.
 Process Design of Distillation Columns 447

Percent: flood
DS

^ 10-'
c
o A

A \
2
c S.
o
c
.2 fs
■*—>
o
2
u.

<0

10-'

Flv
Fig. 8.18 Entrainment Correlation for Sieve Plates'4
(Reproduced with the permission of Chemical Engineering by Access Intelligence, USA)

Weir length fixes area of segmental downcomer. Weir length is normally kept
Process Engineering Channel

in between 0.6 to 0.85 times column diameter. For the first trial calculations, weir
length can be taken as 0.77D, and equivalent down comer area is 12%. Decrease
in weir length increases the net area of tray and decreases the tower diameter, but
it decreases the down comer area, increases the pressure drop in down comer and
also decreases the volume of down comer. It also elevates the liquid level in
down comer. Increase in weir length increases the tower diameter. Hence, bal-
@ProcessEng

anced weir length and weir height are required. Relation between weir length
and down comer area is given in Table 8.34.
Clear liquid depth over the tray is equal to height of the weir, hw, plus the depth
of the crest of liquid over the weir, how. The height of the liquid crest over the
weir can be estimated by using Francis formula (Ref.: 9).
 Introduction to Process Engineering and Design

Table 8.34 Relationship of Weir Length and Down Comer Area

Weir length L Down comer area A.

^=^ —x 100
/D of tower D, Column area Ac

0.600 5.25
0.650 6.80
0.700 8.80
0.705 9.00
0.715 9.50
0.727 10.00
0.745 11.00
0.770 12.00
0.780 13.00
0.800 14.00
0.815 15.00
0.826 16.00
0.840 17.00
0.850 18.00

2
Un
h ow= 750 (8.69)
, Pl /w
where, how = Weir crest of liquid, mm
Lm = Mass flow rate of liquid, kg/s
lw = Weir length, m
pL = Liquid density, kg/m^

8.4.7.5 Checking for Weeping

At a vary low value of vapour velocity liquid rain down through the perforations.
This phenomena is known as weeping. It is again an inoperative condition.
Minimum vapour velocity required to avoid the weeping is given by Eduljee's
equation.

K - 0.9(25.4-d,,)
Process Engineering Channel

min = )= (8-70)
VPv
where, vh min = Minimum vapour velocity through the holes, m/s
d, - Hole diameter, mm
pv = Density of vapour, kg/nr
K = Constant, a function of depth of clear liquid on the plate, which
can be obtained from Fig. (8.19).
@ProcessEng

8.4.7.6 Total Pressure Drop in Sieve Tray Tower

Total pressure drop in sieve tray tower, ApT is given by the following equation.
ApT = Pressure drop in inlet nozzle + Pressure drop/tray x No. of trays
+ Pressure drop in outlet nozzle
 Process Design of Distillation Columns 449

32

31

30

29

28

27
0 20 40 60 80 100 120
(A. mm
Fig. 8.19 Weep-Point Correlation (Eduljee, I959)9
(Reproduced with the permission of Elsevier, UK)

Hence major pressure drop in vapour is provided by trays.

Ap-j^NxAjj, (8.71)
where, N = Total number of sieve trays of tower
A/?, = Tray pressure drop, Pa
Tray pressure drop in Pa or N/m2 can be determined from the tray pressure
drop in mm of liquid by following equation.
Ap. = 9.8 x KT3 h. p, (8.72)
where, Ap, = Tray pressure drop, N/m" or Pa
h, = Tray pressure drop, mm of liquid column (LC)
-j
Process Engineering Channel

pL = Density of liquid, kg/nr

To find the tray pressure drop simple additive model is used.
h
t = hd + iK + Kw) + hr (8-73)
where hd = Pressure drop through dry plate, mm LC
hw = Height of weir, mm
how = Height of liquid crest, mm
hr = Residual pressure drop, mm LC
@ProcessEng

Tray pressure drop (/t,) is the sum of pressure drop which occurs as vapour
rises through the perforations of dry plate (/i(/), pressure drop which occurs as
vapour rises through the pool of clear liquid {hw + how) and pressure drop which
occurs in vapour-liquid disengagement space (/?,.). Due to the high vapour veloc-
ity, froth formation takes place over the tray. Some liquid particles are entrained
in vapour phase. Hence, some additional energy loss is taking place in carrying
 450 Introduction to Process Engineering and Design

the liquid particles. These liquid particles are disengaged from the vapour after
travelling a certain distance. This additional energy loss is counted by residual
pressure drop, hr
Pressure drop through dry plate is given by following equation.

V/.
hd=5\ (8.74)
Pl

where, hd = Dry plate pressure drop, mm LC

y/( = Velocity of gas through the holes, m/s

Volumetric flow rate of gas, m3/s Qv

(8.75)
Total hole area, irr A,,

Pv, Pi = Densities of vapour phase and liquid phases, respectively, kg/m3

C0 = Orifice coefficient which is a function of ratio of plate thickness
to hole diameter and % perforated area of plate. It can be deter-
mined by using Fig. 8.20.

0.95

f/
0.90
/

/
0.85

/ /
c
o
o
£ 0.80 /
O
o /
o y /
o
CJ
y
c
Process Engineering Channel

c /
0.75 / y
/ /

/
>>.
0.70
@ProcessEng

0.65 y
5 10 15 20
Per cent perforated area, (ApAp) x 100

Fig. 8.20 Discharge Coefficient (Sieve Plates)14

(Reproduced with the permission of McGraw-Hill Education, USA)
 Process Design of Distillation Columns

4
% Perforated area = — x 100 (8.76)
Ai
where, Ah = Total area of all active holes of tray, m"
Aa = Active area of tray = Ac - 2 Ad, m2
A = Inside area of column, m2
A(1 = Downcomer area of tray, m"
Residual pressure drop is calculated by the following equation.

12.5 x 103
hr = (8.77)
Pl
where, hl. = Residual pressure drop, mm LC
pL = Density of liquid, kg/m3

8.4.1 J Design of Downcomer

There are two functions of a downcomer:

(a) It provides the passage for the flow of liquid.
(b) Foamy or frothy liquid enters into downcomer. Hence, downcomer also
acts as a vapour-liquid separator. To facilitate the vapour-liquid disengage-
ment, certain minimum residence time (at least 3 seconds) is required in the
downcomer.
Following types of downcomers are used:
(i) Straight segmental downcomer: It is the simplest and cheapest and is
preferred for most applications. In this type, downcomer channel is
formed by a flat plate. The portion of the flat plate which extends down
below the plate from the outlet weir is called apron. With this type of
downcomer, apron is straight and vertical.
(ii) Inclined segmental downcomer: With this type of segmental
downcomer, apron is inclined towards the wall. It is preferred with
foamy liquid, with which vapour-liquid disengagement is difficult.
Inclined or sloppy apron provides more resistance to flow and makes
the phase separation easier. It also increases tray area available for per-
forations. But with this type, liquid back-up in downcomer is higher
Process Engineering Channel

compared to straight segmental downcomer.

(iii) Circular downcomers or pipes: They are used for small liquid flow
rates in a few cases.
Liquid is falling from tray to tray by passing through the downcomer. Due to
the pressure drop across the tray, liquid is flowing from lower pressure to higher
pressure. To overcome the pressure difference liquid elevates its level in the
@ProcessEng

downcomer. This is called liquid back-up in the downcomer. Also some pressure
drop occurs when liquid flows through the downcomer area. Downcomer pres-
sure drop increases the liquid back-up further. Head loss or pressure drop in the
downcomer is estimated by following equation.
 Introduction to Process Engineering and Design

L
hdc=166-^- (8.78)
. Pi An .

where, /idc = Downeomer pressure drop, mm LC

Lmd = Liquid flow rate in down comer, kg/s
pL = Density of liquid, kg/m3
Am = Ad or Aap whichever is smaller, m2
Ad = Downeomer area, m
Aap = Clearance area under downeomer apron, m2

Aap = l'apUl06 (8.79)

where, hap = Height of the bottom edge of the apron above the plate, mm
lw - Length of weir, mm
hap = hw - (5 to 10) mm (8.80)
where, hw = Height of weir, mm
Liquid back-up in downeomer in terms of clear liquid is given by following
equation.
h = (K+ KJ + h, + hdc (8 ■81)
= Downeomer back-up measured from plate surface, mm (i.e.
elevation of clear liquid in downeomer)
Due to the formation of froth and foam, actual height or foamy or frothy liquid
in downeomer is quite great, nearly double than hb.
Density of froth or "aerated" liquid is in between 0.4 to 0.7 times that of the
clear liquid. For design purpose, it is taken as 0.5 times the density of liquid.
Hence, to avoid the downeomer flooding.

i 11 hw
hb * (8.82)

where, hb = Liquid back-up in the downeomer measured from plate surface, mm

/, = Tray spacing, mm
hw = Height of weir, mm
Certain minimum residence lime must be allowed in the downeomer to facili-
tate the disengagement of vapour and liquid phases. Residence time of at least 3
Process Engineering Channel

seconds is recommended. Residence lime in downeomer is given by following

equation.

A i • hbr • Pi
er = (8.83)
L
md
where, Ad = Downeomer area, m2
@ProcessEng

hbc = Liquid back-up in downeomer in terms of clear liquid, m

pL = Density of liquid, kg/m3
Lmd = Liquid flow rate in downeomer, kg/s
 Process Design of Distillation Columns

8.4.8 Step 8: Tray Efficiency and HETP

8.4.8.1 HETP

For the distillation in packed tower, height of packed bed (Z), required for the
desired separation, is determined by following equation.
Z = Nlx HETP
where, N, = Number of theoretical stage required for the desired separation
HETP = Height equivalent to a theoretical plate.
The height of an equivalent equilibrium stage or theoretical plate (HETP) is
the height of packing that gives the same separation as an equilibrium stage.
HETP for the given type and size of random packing is nearly constant and is
nearly independent of the system physical properties. HETP values available in
literature are valid only for good liquid distribution and for the reasonable pres-
sure drop.
HETP values for various packing can be obtained from the Table 8.35.

Table 8.35 HETP for Various Packings

Sr. No. Packing types Packing size, mm HETP. m

1. Pall ring, random 25 0.40 - 0.50

(for AP > 17 mm WC 38 0.60 - 0.75
per m of packing) 50 0.75- 1.00
2. Bed saddle and 25 0.40 - 0.50
Intalox sadle, random 38 0.60 - 0.75
(for AP > 29 mm WC 50 0.75 - 1.00
per m of packing)
3. Raschig rings 25 to 50 mm 1.0 m
4. Structured packings * < 0.5 m
*HETP of a structured packing depends on a factor known as Fv which is defined as

(8 84)
Fv = vg4Pv '
where, v = Superficial vapour velocity, m/s
o
pv = Vapour density, kg/m3
Process Engineering Channel

HETP equal to around 0.5 m is reported for F factor, not exceeding 3, beyond
which pressure drop increases steeply.

8.4.8.2 Tray Efficiency

Like VLE data, in case of tray efficiency also, it is better to predict the tray effi-
ciency based on actual data on the same system or similar system of commercial
@ProcessEng

scale plant or of pilot plant. There is no entirely satisfactory method available for
finding the tray efficiency. Various correlations are available for finding tray effi-
ciency, but they are used only if the reliable actual data on the same or similar
system are not available. Overall efficiency of tray tower is given by following
equation;
 Introduction to Process Engineering and Design

N,
loc = T7- (8-85)

where, N, = Number of theoretical stages required for the desired separation.

Na = Actual number of trays required for the desired separation.
Tray efficienty depends on (i) system composition and properties, (ii) rate of
throughput and (iii) geometry of tray tower (geometry of tray, tray spacing, etc.).
Two methods are given here to find the tray efficiency; (i) Van Winkle's method
and (ii) AIChE method. If actual data for predicting tray efficiency for the given
system are not available, then it can be predicted approximately by using these
two methods. For the safe design calculation, it is suggested that if the value of
tray efficiency obtained based on any of these methods is more than 0.5 then
consider the value of overall efficiency as 0.5.
(i) Van Winkle's Correlation or Method18:
Van Winkle's correlation can be used to predict the tray efficiency of a binary
system of distillation. This corrleation can be used for both bubble-cap and sieve
trays.
rj = 0.07 D/14 ScL025 Reom (8.86)
where, D,, = Surface tension number = (JL/iHL ■ uv) (8.87)
gl = Liquid surface tension, N/m
[lL = Liquid viscosity, N ■ s/m2 or kg/(m ■ s)
u = Superficial vapour velocity, m/s
ScL = Liquid Schmidt number = HLl{pL ■ DLK) (8.88)
2
Dlk = Liquid diffusivity of light key component, m /s

Re = Reynolds number = ^ ^ ^ — (8.89)

^(Fa)
where, h\v = Weir height, mm
pv = Vapour density, kg/m3
Fa = Fractional area =AIJAC
Ah = Area of holes of tray, m2
At. = Inside area of column, nr
(ii) AIChE Method4:
Process Engineering Channel

The point efficiency f] is related to number of transfer units by following

equation.

1
(8.90)
hi(/-7?) NG L NL
where, i] = Point efficiency
@ProcessEng

Ng = Number of gas phase transfer unit

m = Slope of equilibrium curve at the point in consideration
V,L = Molar flow rates of vapour and liquid phases respectively at the
point in consideration
Nl = Number of liquid phase transfer unit
 Process Design of Distillation Columns

The number of gas phase transfer unit is given by following equation.

(0.776 + 4.57 x IQ-3/* - 0.24 Fv + 105 LJ

NCi
0
= — (8.91)
v 7
/ N0.5
Hv
vPvA.
where, hw = Weir height, mm

F
v=
va = Vapour velocity based on active tray area, m/s
Qv Volumetric flow rate of vapour

Aa Active tray area

L = Volumetric liquid flow rate across the plate divided by average
width of plate, m /(s ■ m)

K
Average width of plate = — (8.92)
Zl
ZL = Length of liquid path across the tray, m
IUV = Viscosity of vapour, N • s/m2
pv = Density of vapour, kg/m3
Dv = Vapour diffusivity, m2/s
The number of liquid phase transfer unit is given by following equation
Nl = (4.13 x 108 Dl)0-5 (0.21 Fv + 0.\5)eL (8.93)
2
where, DL = Liquid diffusivity, m /s
0, = Liquid contact time, s
Liquid contact time 0/ can be determined by following equation.

eL = (8.94)
h
where, Z, = Length of liquid path from inlet downcomer to outlet weir, m
Zc = Liquid hold-up on the plate, nr per m" active area
For sieve trays,
Process Engineering Channel

Zc = 0.006 + 0.73 x lO"3 hw - 0.24 x lO"3 Fv hw + 1.22 L/, (8.95)

Tray efficiency ij is equal to the point efficiency /), if the liquid on tray is
perfectly mixed. For the real tray, this may not be true.
Tray efficiency rj can be determined from point efficiency by using Fig. (8.21).
tj mV ■
In this figure, graph of — vs. r\ is drawn for different values of Peclet
@ProcessEng

fj L
number. For a tray, Peclet number is given by following equation.

Z2
Pe = —— (8.96)
DeeL
where, D = Eddy diffusivity, m2/s
 Introduction to Process Engineering and Design

000
lo 700
500
20
300
200
2,6
100
70
50
2.2
30
20
/
10
7
1.6 /
1.4 Z

1 2 3 8 10
{mVi)IL) (wl'ij//.)
(a) . . (b)
11 = Plate Efficiency
1 = Point Efficiency

Fig. 8.21 Relationship between Plate and Point Efficiencies'4

(Reproduced with the permission of McGraw-Hill Education, USA)

For sieve trays, the Eddy diffusivily can be estimated by the following equation.

De = (0.0038 + 0.017 3.86 Lp +0.18 x lO^/tJ2 (8.97)

In actual operation liquid droplets get entrained in vapour phase. This reduces
the value of tray efficiency r\. Actual tray efficiency r]a considering the liquid
entrainment can be calculated by following equation.

0
(8.98)
Process Engineering Channel

I + 77
l-y

where, V = Fractional liquid entrainment.

Liquid entrained

Gross liquid flow

@ProcessEng

In Sec. 8.4.7, various parameters relating lo the process design of a distillation

tower were discussed in general. However, detailed design of the tower internals
are well covered in the book by Billet19. For preparation of the specifications of a
on
tray tower, useful guidelines can be derived from the article by Mukherjee" .
 Process Design of Distillation Columns

Example 8.13
Design a sieve tray tower for the distillation of acetic acid-water system, specified in
Example 8.5. Maximum feed flow rate is 12 000 kg/h and minimum feed flow rate is
8400 kg/h (70% of the maximum).
Solution:
Data obtained from Example 8.5:
(i) Feed composition: 80% acetic acid and 20% water (by mass) or
54.55% acetic acid and 45.45% water (by mole)
(ii) Mole fractions of water: In distillate xD = 0.9302, In residue xw = 1.666 x 10-4
(iii) q= 1.272
(iv) Reflux ratio, R = 4.2
(v) Number of theoretical stages required for desired separation, N = 25
Flow rates:
Average molar mass of feed,
Mav = IXi Mi = 0.5455 x 60 + 0.4545 x 18 = 40.911 kg/ kmol

12 000
Molar flow rate of feed. F = = 293.32 kmol/h
40.911
F=D +W
Fxf = Dxd + Wxw
D + W = 293.22
0.9302 D + 1.666 x lO"41F= 0.4545 x 293.32 = 133.314
0.9302 D+ 1.666 x 10-4 (293.3-D)= 133.314
D = 143.29 kmol/h
W = 293.32 - 143.29 = 150.03 kmol/h
Molar flow rates of vapour and liquid at the top in enriching section;
L = RD = 4.2 x 143.29 = 601.818 kmol/h
V= (R +l)D = 5.2 x 143.29 = 745.108 kmol/h
Molar flow rates of vapour and liquid in slipping section:

L = L + F^ = 601.818 +293.32 x 1.272 = 974.92 kmol/h

V = F (q - I) + V = 293.32 x (1.272 - 1) + 745.108 = 824.89 kmol/h

Tower diameter calculation:
(a) Tower diameter required at top:
Operating pressure at top of column = 1 atm = 101.325 kPa
Process Engineering Channel

V = 745.108 kmol/h
L = 601.818 kmol/h
Here total condenser is used, hence composition of vapour leaving the top most tray
and composition of liquid entering to the top most tray (reflux) are equal.

AL = L = 601^8=0.8077
V 745.108
@ProcessEng

where, L,„, Vm = Mass flow rates of liquid and vapour at the top, kg/s
Density of vapour, pv:

pMav
 Introduction to Process Engineering and Design

Average molar mass of vapour at top

Mav = Lv,- M, = (1 - 0.9302) x 60 + 0.9302 x 18 = 20.9316 kg/ kmol

20.9316 273
Pv = •X
(/r + 273) 22.414

To find the temperature of vapour at top, mt-x-y data, put y = xD = 0.9302 and find
the corresponding value of temperature from Table (8.6).
y=xD = 0.9302 t=rT= 100.64oC
pv = 0.6823 kg/m3
Density of liquid at top, pL:

1
Pl =

Pi

Density of pure water at 100.64oC, pw= 958 kg/m3

Density of pure acetic acid at 100.64oC, pAA = 1010 kg/m3
Mass fraction of water in distillate = 0.8
Mass fraction of acetic acid in distillate = 0.2

1
Pl = = 967.97 kg/m3
0.8 0.2
+
958 1010

Liquid-vapour flow factor at top.

0.5
f
lv = (8.66)
V,w

FiV= 0.8077f Q'6823 1 = 0.021 444

1967.97 ^
For the first trial calculations, tray spacing = 0.3 m (assumed)
From Fig. 8.16,
Cf = 0.0635
Flooding velocity,
Process Engineering Channel

02 N0 5
a PL " Pv '
V
F = C, (8.65)
0.02 Pv
where. vF = Flooding velocity, m/s
(T = Surface tension of liquid, N/m
(7 = Icj, x, = (1 - 0.9302) (7aa + 0.9302 gw
@ProcessEng

where, gw = Surface tension of pure water, N/m = 58 x I0"3 N/m

gaa = Surface tension of pure acetic acid, N/m
gaa at 100.64oC

°A1 = m{p'L-pv) (8.99)

 Process Design of Distillation Columns

aAA = surface tension of acetic acid, dyn/cm

p'L = density of liquid acetic acid, mol/cm3

lOlOx 10 -3
Pl = — = 0.016 833
60 60 cm3
p'v = density of acetic acid vapour, mol/cm3

1 Ts
Pv = X
(273 + 100.64) psVs

1 273
Pv = x = 3.26 x 10-5 mol/cm3
(273 + 100.64) 22 414
[¥] = Parachor can be calculated from Table 3-343, of Ref. 14.
{'F] = 55.5 (Contribution of CH, - ) + 73.8 (Contribution of - COOH)
[F] = 129.3
1/4
(7aa = 129.3 (0.016 833 - 3.26 x lO"5) = 2.1723
(jAA = 22.268 dyn/cm = 22.268 x lO"3 N/m
a = (1 - 0.9302) x 22.268 x lO"3 + 0.9302 x 58 x lO-3
ct = 55.5 x lO-3 N/m

,0.5
55.5 x 10~3 967.97 - 0.6823
vF = 0.0635
002 0.6823

vF = 2.93 m/s
Let actual vapour velocity through tower, v = 0.85 vF
v = 2.49 m/s
Volumetric flow rate of vapour at top

VMm 745.108x 20.9316

Q = = 22 858.4 m3/h = 6.3496 m3/s
Pv 0.6823
Net area required at top

. Q 6.3496 ^ 2
A,, = — = = 2.55 m
v 2.49
Process Engineering Channel

Let downcomer area, Ad = 0.12 A,,

A„ = A(, -At/ = AC-0.I2 A(. = 0.88 Ac.
where, Ac = Inside cross sectional area of tower
0.88 Ac = 2.55

A = — = 2.8977 m2
c 0.88
@ProcessEng

Inside diameter of column required at top

1 1
4 x A(, 4 x 2.8977
D: = = 1.92 m say 1.95 m at the top
 Introduction to Process Engineering and Design

(b) Tower diameter required at bottom:

Operating pressure at the base of column = Operating pressure at top + ApT
where, ApT = Total pressure drop in sieve tray tower
h, = 120 mm WC
ApT = Actual no. of trays x pw g h,
Assuming tray efficiency = 0.5

N 25
Actual number of trays, /V, = — - — - 50
^ " 0.5 0.5
ApT = 50 x 1000 x 9.81 x 120 x 10"3 = 58 860 Pa = 58.86 kPa (assumed)
Operating pressure at base
p, = p, + ApT = 101.325 + 58.86 = 160.185 kPa = 1.58 atm
Bottom product is nearly pure acetic acid. Antoine equation13 for acetic acid

i pv = 15.8667
In .^ - 4097.86
T - 27.4937
When pv= p'r T=Th = Base temperature of column

4()97 86
In (160.185) = 15.8667 -
T -27.4937
T = 407.26 K = 134.260C (Estimated)
Molar flow rates of vapour and liquid at bottom

V = 804.89 kmol/h, L = 91 A.92 kmol/h

At the base of column,

Lw _ L _ 974.92 _ ^

Pw ~ V 824.89
where LW,V w = Mass flow rates of vapour and liquid at bottom, kg/s
Density of vapour at bottom

p'M 160.185 x 60 273

x
Pv = =
RTh (273 + 134.260) 101.325 x22.414

p,, = 2.8368 kg/m3

Density of liquid (nearly pure acetic acid) at bottom
pL = density of acetic acid at 134.260C and at 160.185 kPa
Process Engineering Channel

= 1000 kg/m3 (assumed)

Liquid-vapour flow factor at bottom

- f r, N0.5
Lw Pv_
Flv= =
V vr Pl
@ProcessEng

F,v=L182f^f =0. 062 96

L 1
1000 )

For tray spacing = 0.3 m, from Fig. 8.16

Cf = 0.0616
 Process Design of Distillation Columns 461

Flooding velocity

0.2 ,0.5
o Pl - Py
V
F- (8.65)
0.02 Pv
Surface tension of pure acetic at 134.260C temperature
1/4
^ = MpZ-Pv)

1
p," = 1000 x 10-3 x — =0.016 67 mol/cm3
60

Pv = 2.8368 x = 4.728 x lO"5 mol/cm3

60
.1/4
= 129.3 (0.016 67-4.728 x lO"5) = 2.1493
oAA = 21.34 dyn/cm = 21.34 x 10"3 N/m

/
"•2 //■ ,05
21.34 xl0~3 1000- 2.8368 '
= 0.0616
0.02 2.8368

vF = 1.17 m/s
Actual vapour velocity, v = 0.85 x 1.17 = 0.9945 m/s
Volumetric flow rate of vapour at bottom

VM.dV (824.89x60)/3600
Q = = 4.8464 m3/s
Pv 2.8368

Net area required at bottom

= 4.8464 = 4_8732 m2

0.9945
Inside area of column

4.8732 j- 2
A = = 5.538 nr
0.88
Inside diameter of column required at base
Process Engineering Channel

' 4 x Ac. 4x5.538

D; = = 2.655 m
V ^ \ 7t
Up to 1 m diameter 0.3 m tray spacing is sufficient. Here, tower diameters are greater
than 1 m. Hence, for the 2nd trial calculations, increase the tray spacing to 0.45 m.
For tray spacing = 0.45 m
(a) Tower diameter required at top:
@ProcessEng

For Flv= 0.021 44 and tray spacing = 0.45 m

From Fig. 8.16,^ = 0.0814

0.0814
vF - x 2.93 = 3.756 m/s
0.0635
Actual vapour velocity, v = 0.85 vF = 3.1926 m/s
 Introduction to Process Engineering and Design

Net area required

A.. = 63496 = 1.989 nr

" 3.1926

A, ,
A„ = —^ = 2.26 m2
0.88
Inside diameter at top

4x2.26

H—=L7m
(b) Tower diameter required at bottom:
For Flv = 0.062 96 and tray spacing = 0.45 m
From Fig. 8.16, C}= 0.0794

0.0794 . ...
vF = x 1.17 = 1.5 m/s
0.0616
Actual vapour velocity, v = 0.85 vF = 1.275 m/s

Net area required. A., = = 3.8 m2

1.275
Inside diameter of column required at bottom

A, ,
A = = 4.32 m2
c 0.88
Inside diameter of column required at bottom

4x4.32
D, = J = 2.345 m say 2.36 m

Provide different diameters in two different sections.

Table 8.36 Summary of Calculations

Enriching Section Stripping Section

D, = 1.7 m D, = 2.36 m
Ac = 2.27 m2 Ac= 4.374 m2
Process Engineering Channel

A,, = 1.998 m2 A,, = 3.85 m2

Downcomer area, A(/ = 0.2724 nr A^ = 0.525 m2
Active area, A„ = 1.7252 m2 An = 3.3242 nr
Hole area. A,, = 0.172 52 m2 A,, = 0.332 42 nr

For the 1st trial, hole area A,, is taken as 10% of active area, Air
Volumetric flow rate of liquids:
@ProcessEng

LMav 601.818x20.9316
In enriching section, QL =
p, 967.97

= 13.0138 m3/h = 3.6 x H)"3 m3/s

 Process Design of Distillation Columns

In stripping section

ZM,,v 974.92x60 , , ,
Q, = —= = 54.495 m /h = 16.25 x lO"3 m3/s
p/ 1000

Refering Table 8.33, single pass tray can be used for both sections.
Check for weeping:
Minimum vapour velocity through holes to avoid the weeping is given by following
equation.

K — 0.9(25.4 - dh)
vhmin = — (8.70)
VPv
where, K = constant can be obtained from Fig. 8.19 is a function of (hw + how)
Take
Weir height, hw = 50 mm (For both sections)
Hole diameter, dh = 5 mm (For both sections)
Plate thickness, r = 5 mm (For both sections)
(a) For enriching section:
Height of liquid crest over the weir
-^2/3
m
= 750 (8.69)
Pi.1VV
For the checking of weeping conditions minimum value of how at 70% turn down
must be determined. Minimum value of
Lw = 0.7 LMav = 0.7 x 601.818 x 20.9316
Lw = 8817.9 kg/h = 2.45 kg/s (minimum)
pL = 967.97 kg/m3
Referring Table 8.34, for AJAC = 0.12, /,,/Z), = 0.77
lw = Length of weir = 0.77 D,
/„, = 0.77 x 1.7 = 1.309 m
\2/3
2.45
Minimum/r,,,,, = 750 = 11.64 mm
967.97xl.309

At minimum rate, hw + hnw = 50 + 11.64 = 61.64 mm

Process Engineering Channel

From Fig. 8.19. AT =30.38

30.38-0.9(25.4-5)
v
h min = ^ = 14.552 m/s
(0.6823 ),)-5
Actual vapour velocity through holes at minimum vapour flow rate,

0.7 d. 0.7 x 6.3496

@ProcessEng

vhtl = = = 25.76 m/s

Ah 0.172 52

Hence, vha > vh min

Thus in the enriching section, minimum operating rate is well above weep point,
(h) For stripping section:

Minimum value of LH. = 0.7 x Lw = 0.7 x 974.92 x 60

 Introduction to Process Engineering and Design

Minimum = 40 946.64 kg/h = 11.374 kg/s

pL = 1000 kg/m3
L = 0.77x2.36= 1.8172 m
v2/3
11.374
Minimum = 750 = 25.47 mm
1000x1.8172

At minimum rate, hw + how = 50 + 25.47 = 75.47 mm

From Fig. 8.19. K = 30.69

30.69-0.9(25.4-5)
v
h min = 7.32 m/s
0.5
(2.8368)
Actual vapour velocity through holes at minimum vapour flow rate

0.7 x a 0.7 x 4.8464

v
ha = = 10.2054 m/s
0.332 42
Hence, vha > vh „„„
In stripping section also, minimum operating rate is above the weep point.
Tray pressure drop:
(a) Tray pressure drop for enriching section
Dry plate pressure drop

v X2
h P„
hd = 5V (8.74)
vQ/ L

a 6.3496
V/, = = 36.8 m/s (maximum)
0.172 52
pv = 0.6823 kg/m3, pL = 967.97 kg/m3

Plate thickness A, A,
From Fig. 8.20, for = 1 and = 0.1, C,, = 0.8422
Hole diameter Ap Aa

(A = Perforated area is slightly less than active aera, AJ

36.8 v 0.6823 ,0 T n
^ = 51 x = 68.64 mm LC
0.84227 967.97
Process Engineering Channel

hw = 50 mm LC
Miximum height of liquid crest over the weir
2/3 / x2/3
Av 2.45/0.7
Maximum how =750 = 750 = 14.765 mm LC
V PlK
l'W y 967.97 x 1.309

Residual pressure drop.

@ProcessEng

12.5x10-
h.. = (8.77)

12.5 xlO3
h.. = = 12.9136 mm LC
967.97
 Process Design of Distillation Columns

Total tray pressure drop

h, = hd + (hw + how) + hr (8.73)
h, = 68.64 + (50 + 14.765) + 12.9136 = 146.32 mm LC

Note: This is equivalent to 142 mm WC. Tray pressure drop was assumed equal to 120
mm WC to estimate the base pressure. The calculations can be repeated with a revised
value of tray pressure drop but small changes in physical properties will have little
effect on the tray design. However, correct estimate of base temperature is required
and is important for the reboiler design.
(b) Tray pressure drop for stripping section:
Dry plate pressure drop, hd:

4.8464 . . ,
v,, = = 14.58 m/s
0.332 42
pv = 2.8368 kg/m3, pL = 1000 kg/m3, C0= 0.8422 (From Fig. 8.20)

V 0.8422 J 1000
hd = 43.36 mm LC
hw = 50 mm LC
Maximum height of liquid crest over the weir
\2/3
11.374/0.7
K,..
*o\v = 750 = 32.31 mm LC
1000x1.8172

Residual pressure drop

12.5 x 10
hr = = 12.5 mm LC
1000
Total tray pressure drop
h, = 43.36 + (50 + 32.31) + 12.5 = 138.17 mm: say 140 mm LC
Checking of downcomer design:
Types of downcomer: Straight and segmental downcomer area, = 0.12 Ac(For both
sections)
(a) For enriching section:
Process Engineering Channel

Pressure drop in downcomer is given by following equation.

Kui
hdc = 166 (8.78)
PlKi
Lind = Liquid flow rate through downcomer, kg/s
@ProcessEng

Lmd = LM = 601.818 x 20.9316 x —1—

3600

= 3.5 kg/s
pL = 967.97 kg/m3
Am = Ad or Aap, whichever is smaller, m2
Ad = 0.2724 m2
Aap=hapXlw
 Introduction to Process Engineering and Design

C = 1.309,
h
ap=K>- 1°
= 50 - 10 = 40 mm = 0.04 m
Aap = 0.04 x 1.309 = 0.052 36 m2
Aap « Therefore, take Am = Aap.
Am = 0.052 36 m2
/ \2
3.5
/?dc = 166
967.97 x 0.052 36

^dc = 11-79 mm, say 1 mm

Liquid back-up in downcomer

K= + Kw + hi + hdc (8.81)
hh = 50 + 14.765 + 144.25 + 1 = 210 mm

/, + hw 450 + 50
= = 250 mm

I, + h
hh = 210 <
2
Downcomer area and tray spacing are acceptable.
Check residence time:

A , hb P,
Qr = ^ (8.83)
Kid

0.2724 x 0.210 x 967.97

= 55
{hbc - hh = 210 mm)
9,.= 15.82 s >3 s
Hence, it is satisfactory.
(b) For stripping section:
Pressure drop in downcomer

/ \-
Process Engineering Channel

11.374/0.7
hdc = 166
1000xAm j
2
Downcomer area, Ad = 0.525 m
A — hop - Iw
^ap
hap = 50 - 10 = 40 mm. lw = 1.8172 m
Aap = 0.04 x 1.8172 = 0.0727 m2
@ProcessEng

Am = 0.0727 m2
hd(. = 8.29 mm
Liquid back-up in downcomer
hb=hw+ hoW + h, + h<ic
hu = 50 + 32.31 + 140 + 8.29 = 230.6 mm
 Process Design of Distillation Columns

I, + hw 450 + 50
= 250 mm
"2 ~ 2

+
h K
hu = 230.6 <
2
Here, downcomer area and tray spacing are acceptable.
Residence time in downcomer

AilhbPL 0.525x0.2306x1000

''= =
(11.374/0.7)
= 7.45 s > 3 s
Hence, it is satisfactory.
Checking of entrainment:
(a) For enriching section:

Q_
Vapour velocity based on net area, vn =
aT

6.3496 , .
v.,
'n = = 3.178 m/s
1.998

V 'J j 7c
% flooding
h
= — x 100 = x 100 = 85 %
vf 3.756

Flv = 0.021 444, ^ = 0.21 (from Fig. 8.18)

% entrainment = 21 %> 10%
If is less, then higher tray efficiency is obtained. But to decrease the value of ^P, tower
diameter must be increased further. Ideally, optimum value of'F must be determined for
the given case. Optimum value of ¥ can be greater than 0.1 or 10%.
(b) For stripping section:
% Flooding = 85 %, FLV = 0.062 96
From Fig. 8.18 4* = 0.084
% entrainment = 8.4% < 10%
It will provide higher tray efficiency.
Process Engineering Channel

Tray efficiency by AlChE method:

(a) For enriching section:
Physical properties of liquid and vapour for the same tray are
p, = 967.97 kg/m3, 0, = 55.5 x 10-3N/m
fiL = Viscosity of reflux or distillate (water-acetic acid solution at
10().64oC)
In pL = viqln Jul + w2ln fa
@ProcessEng

wl = 0.8 = mass fraction of water

h,2 =0.2 = mass fraction of acetic acid
fa. = Viscosity of pure water at 10().64oC = 0.28 mPa • s or cP
jUAA = Viscosity of pure acetic acid at 10().64oC = 0.48 mPa- s or cP
(Fig. 3^13 of Ref. 14)
fa = 0.312 mPa ■ s or cP = 0.312 x lO"3 (N ■ s)/m2
 Introduction to Process Engineering and Design

Diffusivity of acetic acid in water at I00.64oC

D, = 1.24 x lO-5 cm2/s at 250C
(Table 3.319 of Ref. 14)
To find at 100.64oC,

dlH
= constant
r
where, /j = Viscosity of solvent (water)
0
Hw at 25 C = 0.95 mPa s or cP

1.24 x 101-5 x 0.95 (273 + 100.64)

DL = x
l 273 + 25 ) 0.28

D, = 5.275 x K)"5 cm2/s = 5.275 x lO"9 m2/s

For vapour:
pv = 0.6823 kg/m3
pv = Viscosity of vapour mixture

y, A
ZyijQij

vl/2 1/4
Mj
i+
M:

©7 = 1/2

1+

/ \
V,
and Q =
ij M:

(Eq. (3-87) to (3-89) of Ref. 14)

Viscosity of acetic acid vapour at l()0.64oC
pA = 1000 x I0"7 poise = 0.01 cP or mPa- s (/ for acetic acid)
Viscosity of water vapour at 100.64oC
jU,,, = 1250 x 10-7 poise = 1250 x 10"5 cP or mPa ■ s (j for water)
Process Engineering Channel

1/4 2
1 + (1000/ n 18/
T 250.j i /60
Q = 0.4691
u= 1/2
60 |
1+
isJ
@ProcessEng

ri250V60^x0.4691 = 1.9546
VIoooA18j
y • = 1 - 0.9302 = 0.0698, yy = 0.9302

(0.0698 x 0.01) + (0.9302 x 0.0125)

pv =
(0.9302 x 0.4691) + (0.0698 x 1.9546)
 Process Design of Distillation Columns 469

Hv = 0.0215 cP or mPa-s = 0.0215 x lO"3 (N ■ s)/m2

Dv = Diffusivity of acetic acid vapour in water vapour.

\_
-3 1 75
d _ IQ 7- [{Ma +Mw)I{MaMw)¥

p[(iv)^+(iv);-r

where, Dv is in cm2/s. 7 in K, p is operating pressure in atmosphere, MA and Mw are

molar masses and IV is atomic diffusion volume.
(Equation 3-133 of Ref. 14. EV can be determined by using Table-342 of the same
reference)
For acetic acid (CH3COOH)
(EV)^ = 2 x 16.5 + 4 x 1.98 + 2 x 5.48 = 51.88
For water (H20),
(EV)W = 2 x 1.98 + 5.48 x 1 = 9.44
T = 211+ 100.64 = 373.64 K

10"3 x (373.64)'75 [(60 +18)/(60 x 18)]l/2

Z), =
lx[51.88l/3+9.44l/3]2

Dv = 0.25 cm2/s = 0.25 x K)"4 m2/s

Number of gas phase transfer units is calculated by following equation

0.776 + 4.57 x KT3 h - 0.24 Fv +105 L

Nc= (8.91)
n0.5
Fv
Pv Dv

hw = weir height = 50 mm

F
v = VaJi\ (8.84)

. . Qvmin' 0.7 Qv
va = Vapour velocity based on active tray area = =
A A
a a
0.7x6.3496 ,
= = 2.5764 m/s
Process Engineering Channel

1.7252

Fv = 2.5764 >/ 0.6823 =2.128

^ Volumetric flow rate of liquid

p
Average width of plate
@ProcessEng

_0.1xQL _ 0.7 x 3.6x 10-3

L"~ (K/Ztf I-12521ZL

where, ZL = Length of liquid path

= Horizontal distance between weir and downcomer apron
 Introduction to Process Engineering and Design

Using Mathematical Table 1.19 a of Ref. 14.

L = 2—= 2 x 0.77 = 1.54

D12 D
Chord h is given by

— = 0.362
R

0.362 x D.
h = =0.181 D:
2
= 0,-2/2 = 0,-2x0.181 0, = 0,(1 - 2x0.181)
ZL = 0.638 x O,. = 0.638 x 1.7 = 1.0846 m
Lp = 1.5843 x lO"3 m2/s

u 0.0215 xlO"3
= 1.26
PvDv 0.6823 x 0.25 xl O-4

(0.776 + 4.57 x 10"3 x 50 - 0.24 x 2.128 +105 x 1.5843 x 10"3)

NG=
A/l26
Nc = 0.588
Liquid hold-up on the plate, m per m active area, Zc is given by equation
Zc = 0.006 + 0.73 x lO"3 hw - 0.24 x K)"3 Fv hw + 1.22 Lp (8.95)
= 0.006 + (0.73 x 10-3 x 50) - (0.24 x 10"3 x 2.128 x 50)
+ (1.22 x 1.5846 x lO"3) = 0.0189 m3/m2
Liquid contact time
Z Z
c L
eL = — (8.94)
l
p

0.0189x1.0846
ei = — = 12.94 s
1.5843 xlO-3

Number of liquid phase transfer unit

Nl = (4.13 x 108 DLf 5 (0.21 Fv + 0.15) eL (8.93)
Process Engineering Channel

8 9 05
= (4.13 x 10 x 5.275 x lO" ) (0.21 x 2.128 + 0.15) x 12.94= 11.4
Eddy diffusivity D(, for sieve tray can be estimated by following equation.
De = (0.0038 + 0.017 v0 + 3.86Lp + 0.18 x lO"3 hw)2
= (0.0038 + 0.017 x 2.5764 + 3.86 x 1.5843 x K)"3 + 0.18 x K)"3 x 50)2
= 0.003 93 m2/s
2 2
@ProcessEng

Peclet number Pe = —-— = ' -^^46 =23.13 (8.96)

DeeL 0.003 93x12.94
Point efficiency, r\
/ \
1 rI 11 .+ mLx 11 ^
(8.90)
In(l-p) \Ng L Nl y
 Process Design of Distillation Columns 471

Slope of equilibrium curve of top tray

1/3
0.9703 x ( 0.9409 ^ f 0.9186
m = —=
x 0.9578 J 10.9134 J10.8787
(Value of y and x are obtained from vapour-liquid equilibrium data, given in Example
8.5)
m = (1.0136 x 1.0301 x 1.0454)1/3 = 1.0296

mV 1.0296x745.108
— = = 1.2747
L 601.818
Note: At 70 % turndown, individual values of V and L will change, but value of ratio
V/L will remain constant.

I 1
+1.2747 x 1

0.588 11.4
In (i - 77)
f) = 0.424

mV
n = 1.2747 x 0.424 = 0.54 and Pe = 23.13
L
From Fig. (8.21)

n
- = 1.297
n
Efficiency of sieve tray rj = 1.297 x 0.424 = 0.55
Actual tray efficiency r]a, considering liquid entrainment

na=- (8.98)
1+1
l-l1

0.55
na = = 0.4798
0.21
I + 0.55
1-0.21

(b) For stripping section:

Process Engineering Channel

To find the tray efficiency of the bottom most tray of stripping section, physical proper-
ties of liquid and vapour of the same tray are required.
Liquid:
p" = 1000 kg/m3
a, = 21.334 x 10-3N/m
Viscosity of acetic acid liquid at 134.260C
@ProcessEng

liL = 0.34 mPa-s or cP = 0.34 x 10"3 kg/ (m ■ s)

Diffusivity DL at 134.260C

1.24 x 10"5 x 0.95 (273 + 134.26)

D, = x
( 273 + 25) 0.28
= 5.75 x lO"5 cm2/s = 5.75 x lO"9 m2/s
 Introduction to Process Engineering and Design

Vapour:

p" = 2.8368 kg/m3

pv = 0.009 mPa s or cP

1Q"3 x (407.26[(60 +18)/(60 x 18)]'72

Dv =
(1.58) [51.88l/3 +9.44l/3]2

= 0.1839 cm2/s = 0.1839 x lO"4 m2/s

Number of gas phase transfer unit:
Vapour velocity based on active area

0.7 x Qv 0.7 x 4.8464

v. = = 1.02 m/s
3.3242

Fv = 1.02 V 2.8368 = 1.718

0.7 x Q, 0.7 x 16.25 x 10~3

£ = -
" (AJZl) 3.3242/ZL

ZL = 0.638 Z), = 0.638 x 2.36 = 1.5 m

L= 5.1328 x 10-3 m2 /s

-3
0.009x10
= 0.1725
-4
Pr Dv 2.8368x0.1839x10

-3 ■
0.776 + (4.57 x 10"3 x 50) - (0.24 x 1.718) + (105 x 5.1328 x I ()"J)
Nr =
V 0.1725
= 2.7234
Liquid hold-up on the plate,
Zc. = 0.006 + (0.73 x 1 (L3 x 50) - (0.24 x 10_3 x 1.718 x 50)
+ (1.22 x 5.1328 x lO"3) = 0.028 m3/m2
Liquid contact time

zczL 0.028x1.5
dL = = 8.18 s > 3 s
5.1328x10i-3
Process Engineering Channel

L.
-p

Number of liquid phase transfer units,

^ = (4.13 x 108 x 5.75 x KT9)0"5 (0.21 x 1.718 + 0.15) x 8.18 = 6.44

Point efficiency, fj
/ —
1 1 V 1 1
hm 2.5x^M9X 1 (8.90)
@ProcessEng

In (1 -1?) v^c LN
l 2.7234 974.92 6.44

77 =0.7625

mV 894 89
77 = 2.5 x 0.7625 x = 1.613
I 974.92
 Process Design of Distillation Columns 473

Eddy diffusivity
De = (0.0038 + 0.017 va + 3.86 Lp + 0.18 x K)"3 hw)2 (8.97)
= (0.0038 + 0.017 x 1.02 + 3.86 x 5.1328 x lO" + 0.18 x lO"3 x 50)2
3

= 0.0025 m2/s
Peclet number

1.5
Pe = = 110 (8.96)
DpeL 0.0025x8.18

From Fig. 8.21,

- = 2.46

f] = 2.46 x 0.7625 = 1.876

Efficiency cannot be greater than 1.
Hence r] = 1
Actual tray efficiency r\a considering liquid entrainment

1
Pa = = 0.916
0.084
1+1 1
1+
l- ? I - 0.084

Tray efficiency by Van Winkle's correlation:

For the top most tray
014
77 = 0.07 D 5c/25 Reom (8.86)

where. D„ = Surface tension number = (8.87)

u l uv
i-3 (N • s)/m
o, = 55.5 x lO"3 N/m, ^ = 0.312 x 10^

6.3496 6.3496
uv = Superficial vapour velocity = - = 2.797 m/s
K/AD- (KIA){\.1)'

-3
55.5x10
Dn = = 63.6
0.312 xl0"3x 2.797
Process Engineering Channel

Fi = Fractional area = = 0.07718

4

Pl
Liquid Schmidt number. ScL = (8.88)
PlDlk
@ProcessEng

pL = 967.97 kg/ m3, DLK = 5.275 x lO"9 m2/s

-3
0.312x10
5^ = = 61.1
967.97x5.275x10i-9
 474 Introduction to Process Engineering and Design

Reynolds number.

hwuvpv 0.05 x2.797x0.6823

Re = x KT 3 = = 3962.6 (8.89)
1-3
Pl^A) 0.312x10^X0.07718
i] = 0.07 (63.6)014 (61.1)025 (3962.6)008
= 0.679,

0.679
'la = " = 0.5752
0.21
1 + 0.679
1-0.21

For the bottom most tray:

Surface tension number

o,
D
<= (8.87)
VLUv
(7/ = 21.334 x 10-3 N/m, pL = 0.34 x lO""3 kg/(m ■ s)
4.8464
uv = Superficial vapour velocity = = 1.108 m/s
(7r/4) (2.36)'

21.334x10,-3
D„ = = 56.63
s
0.34xl0_3x 1.108
p, = 1000 kg/m3, D, = 5.75 x IO"9 m2/s

u. 0.34 xlO-3
Sc = = = 59.13
PlDl 1000x5.75X10,-9

A, 0.332 42
F. = = 0.076
^C- 4.374

hw uv pv x 10 -3 0.05 x1.108x2.8368
Re =
0.34 x 10-3 (0.076)
Pl^A)
= 6082
r\ = 0.07 (56.63)°"14 (59.31)0"25 (6082)0 08
Process Engineering Channel

77 = 0.6863

1 0.6863
/ \ = 0.6457
0.084
l + r? 1 + 0.6863 -
l-y 1^1 - 0.084
@ProcessEng

Table 8,37 Resulting Data of Tray Efficiency

Tray efficiency
Method Top most tray Bottom most tray

AIChE Method 0.4798 0.916

Van Winkle's Method 0.5752 0.6457
 Process Design of Distillation Columns 475 |

Let tray efficiency for enriching section = 0.45 and

tray efficiency for stripping section = 0.5

Actual number of trays in enriching section = = 16

0.45
Actual number of trays in stripping section = 18/0.5 = 36
Actual number of trays = 18 + 36 = 54, assume 55.
Feed nozzles can be provided at 32nd, 36lh and 40"d trays. More number of feed noz-
zles are provided to facilitate the flexibility in the operation. For example, in actual
operation if the feed is introduced on 36,h tray, purity of distillate could be more than
desired but bottom product (in this case it is pure acetic acid) may not be of desired
purity. In such a case to get desired result, feed can be introduced on 32nd tray.
Pressure drop:
Pressure drop in the top most tray = 146.32 mm LC
Pressure drop in the bottom most tray = 140 mm LC
Assume tray pressure drop for the entire column =145 mm LC
pL (at top) = 967.97 kg/m3, pL (at bottom) = 1000 kg/m3
ApT = 55 x 145 = 7975 mm LC
ApT = 7975 x 10"3 x 1000 x 9.81 = 78 235 N/nr = 78.2 kPa

8.5 BATCH DISTILLATION

It is a very common unit operation used in the manufacturing of chemicals which

are produced in batch processes. Batch distillation is carried out with or without
using a rectification column (tray tower or packed tower). Thus, it is divided in
two types; (i) simple distillation and (ii) batch distillation with rectification.

8.5.1 Simple Distillation

This type of batch distillation consists of a heated vessel (coiled vessel or jacketed
vessel or kettle type reboiler), a condenser and one or more receiving tanks. Feed
mixture is charged into the vessel and brought to boiling. Vapours are condensed
and condensate is collected in the receiver. No reflux is returned (Fig. 8.22).
Simple batch distillation provides only one theoretical plate of separation. In
some batch reactors of small plants, at the end of reactions, volatile components
Process Engineering Channel

Condenser

L Cooling
Water
@ProcessEng

Fig. 8.22 Simple Batch Distillation

 476 Introduction to Process Engineering and Design

are separated from high boiling liquid solution by simple distillation. Following
equation is applicable to the simple batch distillation.

/
Mj dx
In 'Jl = In = J (8.99)
M, y-x

where, M, = F = Moles of liquid in initial condition

My = W = Moles of liquid in final condition
xF = Mole fraction of more volatile component in liquid phase in
initial conditions
xB = Mole fraction of more volatile component in liquid phase in
final conditions
y = Mole fraction of more volatile component in vapour phase
If the liquid mixture is a binary mixture for which relative volatility oc is con-
stant, then above Eq. (8.99) can be converted into following equation.

\ xB {I-xF) l-xF
In In + In (8.100)
Mii (oc-1) xF (l-xB) _! - _

For the binary system and for simple batch distillation following equation is
also applicable.

M Af M Bf
In (8.101)
M Ai M Bi

where, MAf = Moles of component A in the pot after distillation

MAi = Moles of component A in the pot before distillation
MBj, MBf = Moles of component B in the pot before and after distillation
respectively.
A, B = Components of binary system

Example 8.14
Process Engineering Channel

1000 kg of feed, containing 30% by mass ethylene glycol and remaining water, is charged
to a batch still. Simple batch distillation is carried out at 30.4 kPa absolute pressure to
get the residue which must contain 95% by mass ethylene glycol. Find the amount of
residue (final product).

Table 8.38 Vapour - liquid Equilibrium Data of Ethylene Glycol-Water System at 30.4 kPa a 14
@ProcessEng

Temperature, 0C x y

69.5 1.00 1.000

76.1 0.77 0.998
78.9 0.69 0.997

(Contd.)
 Process Design of Distillation Columns 477

Table 8.38 (Contd.)

83.1 0.60 0.990
89.6 0.46 0.980
103.1 0.27 0.940
118.4 0.15 0.870
128.0 0.10 0.780
134.7 0.07 0.700
145.0 0.03 0.530
160.7 0.00 0.000

Solution:
For simple batch distillation following equation is applicable.

' M, ' dx
Inf—1 = In = I y-x (8.99)
VW MF
F = Mj = moles of liquid feed
Feed contains 300 kg ethylene glycol and 700 kg water.
Molar mass of water =18
Molar mass of ethylene glycol = 62
^ .. 300 , 700 . .
F=M = + = 43.7276 kmol
' 62 18
Mole fraction of water in feed
700/18
X
F- = 0.8893
43.7276
Mole fraction of water in residue
5/18
xB - = 0.153 47
(5/18)+(95/62)

0.8893
43.7276 dx
In
= J X
0.153 47 y
To solve this integration, following table is prepared based on the given VLB data as
well as based on the equilibrium curve drawn.
Process Engineering Channel

Table 8.39 Reference Points of Fig. 8.23

1
X y y-x
y-x

0.153 47 0.875 0.721 53 1.3859

0.270 00 0.940 0.670 00 1.4925
@ProcessEng

0.350 00 0.970 0.620 00 1.6129

0.460 00 0.980 0.520 00 1.9230
0.600 00 0.990 0.390 00 2.5641
0.690 00 0.997 0.307 00 3.2573
0.770 00 0.998 0.228 00 4.3900
0.889 30 0.999 0.109 70 9.1158
 Introduction to Process Engineering and Design

10

/
/
/

/
/
/
/

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Xw
Fig. 8.23 Evaluation of Integral for Batch Distillation

1
Draw the graph of vsx (Fig. 8.23)

0.8893
dx
= area under curve from xB to xF = 2.0643 (integral value)
0.153 47 y-x

' 43.7276'
In = 2.0643
MF
Process Engineering Channel

B = Mf = 5.5493 kmol

(1 - Xn) M
B h
% recovery of ethylene glycol in final product (M,) = x 100
{\-xF)Mi

(1-0.15347)5.5493
x 100
(1-0.8893)43.7276
@ProcessEng

= 97.05 %

8.5.2 Batch Distillation with Rectification

Simple batch distillation is a single stage separation hence it does not give good
separation unless the relative volatility is very high. In many cases, a rectification
 Process Design of Distillation Columns

column which may be a tray tower or a packed tower with reflux is used to im-
prove the performance of batch distillation. If the column is not too large, then it
is mounted on top of the still or heated vessel (Fig. 8.24).

Condenser
Heat out
>-

Reflux

Column
Overhead
product

Feed
Reboiler
Heat in
0000000000 Bottom product

Fig. 8.24 Batch Distillation with Rectification Column

This type of batch distillation consists of a still (heated vessel or reboiler), a

rectification column, a condenser, some means of splitting off a portion of the
condensed vapour (distillate) as reflux and one or more top product receivers. In
operation, a batch of liquid feed is charged to the reboiler or still. Then first,
batch distillation is carried out under total reflux. After achieving steady state,
portion of the overhead condensate is continuously withdrawn in accordance
with the established reflux policy. To get the constant overhead composition, the
amount of reflux returned to the column must be continuously increased throughout
the run. An alternate method of running a batch distillation is to fix the reflux
ratio constant and let the overhead product purity vary with time, stopping the
distillation when the amount of product or the average concentration in the total
Process Engineering Channel

product reaches a certain value.

8.5.2.1 Process Design of Binary Batch Rectification with

Constant Overhead Composition14
Since compositions within column are continuously changing during the batch
distillation, rigorous calculation methods are extremely complex. For a binary
@ProcessEng

system, approximate but useful method is based on McCabe-Thiele graphical

method. In addition to the assumptions of McCabe-Thiele method (negligible
heat of solution and equimolar overflow on the trays), this approximate method
assumes negligible hold-up of liquid on the trays in the column and in the con-
denser. Stepwise procedure of this approximate method is as follows.
 Introduction to Process Engineering and Design

(i) Determine the minimum reflux ratio by using following equation.

= {LIV )min
(8.102)
min

where, = Minimum internal reflux ratio

VV
^ ''min
(^/V)min is determined by using following equation.

yo - ypi
(8.103)
V 'mm Xo-xPi

where, xD = yD = Mole fraction of more volatile component in distillate, if

total condenser is used.
For partial condenser,
yD = Mole fraction of more volatile component in distillate vapour
xD = Mole fraction of more volatile component in reflux
Xpi = xF= Mole fraction of more volatile component in liquid feed
ypj = Value of y which is in equilibrium with xF which can be deter-
mined from the vapour-liquid equilibrium curve or data or
equation. xpj and ypj defined above are valid only for normal
equilibrium curve, as shown in Fig. 8.25.

1.0
Equil ibriun
curve
i
g-
> 0.8
_c Opi :ratinj.
< lint y
/
C
.2
o y
,2 0.6
-2
"o /
Process Engineering Channel

0.4 f

-Vj
+
/?.„ •
0.2 7 /

/ /
@ProcessEng

0 /
0 0.2 0.4 0.6 0.8 1.0
Mole fraction A in liquid
Fig. 8.25 Determination of Minimum Reflux for Equilibrium Curve without Inflection
 Process Design of Distillation Columns 481

1.0

0.8 >1 /
IVy'

/
0.6

y /

0.2 /

0 /
0 0.2 0.4 0.6 0.8 1.0
x
Fig. 8.26 Determination of Minimum Reflux for Equilibrium Curve with Inflection

But for the equilibrium curve with inflection as shown in Fig. 8.26, xpi
and ypi are equilibrium compositions corresponding to the inflection point.
" p"

(ii) Actual reflux ratio is 1.5 to 10 times minimum. Decide the actual reflux
ratio R for starting of batch distillation. Determine the value of internal
reflux ratio L/V required for starting condition.
(iii) Draw the operating line for starting of batch distillation. Slope of operating
line is L/V (for starting condition). Determine the number of theoretical
stages required for the desired separation at the start of batch distillation.
To find this, start the stair case construction from xD to xF in between equi-
librium curve and operating line.
Process Engineering Channel

(iv) Select the slightly higher value of R and L/V than the same of starting con-
dition. For this new value of L/V draw the operating line fromA"D. Draw the
same number of steps (or equilibrium stages) from xD which was obtained
for starting condition. Find the composition of liquid in reboiler (xwi) corre-
sponding to new value of R and L/V.
(v) Select again slightly greater value of R and L/V. Draw the operating line for
@ProcessEng

the new value of L/V. Find the composition of liquid in reboiler or still
(residue), xwi, by drawing the same number of steps from xD which was
required for starting condition. Continue these calculations until, new value
of xwj obtained, is equal to xB, where xB is equal to mole fraction of more
volatile component required in bottom product.
 Introduction to Process Engineering and Design

(vi) Time required for batch distillaiton rectification and with constant over-
head composition can be calculated by Bogart equation14.
X
F(xd-xf)'1. dxw
6= — (8.104)
v la-L/v)^-^)2

where, 6 = Total time required in batch distillation with rectification, s

F = Total moles of feed charged, kmol
V = Molar flow rate of vapour phase, kmol/s
L = Molar flow rate of liquid phase, kmol/s
xD = Mole fraction of more volatile component in distillate
xB = Mole fraction of more volatile component in bottom product
or final residue.
xw= Mole fraction of more volatile component in liquid inside the
still or reboiler
xF = Mole fraction of more volatile component in feed
Above equation can also be written as

F(xd-xf) ;■ dxw
0= „ J (8.105)
^ xwi {\-LIV){xD-xw)2

where, xwi = Intermediate composition (mole fraction of more volatile com-

ponent) of liquid in still or reboiler.
By using Eq. (8.105), for the different values of 0, LIV and R can be
determined. Based on these data, the graph of R vs 0 can be developed.
This graph or curve is also useful in actual operation, giving information
about how to increase the value of reflux ratio R with time to maintain the
constant composition of overheard (top) product.
(vii) The quantity of distillate at any time 0 can be determined by using the
following equation,

F (xF - xwi)
F-Wi = — (8.106)
x
d - xWi
Process Engineering Channel

where, W, = Moles of liquid in still at any time 6, kmol

At the end of distillation, quantity of material distilled

F{xf- xB)
D = F-B= — (8.107)
( XD
where, B = Moles of final bottom product, kmol
(viii) Decide the material of construction of packed tower or tray tower.
@ProcessEng

(ix) Select the type of tower; tray tower or packed tower

(x) Determine the tower diameter and pressure drop per unit height or tray.
(xi) Determine the tray efficiency of tray tower or HETP in case of packed
tower.
 Process Design of Distillation Columns

(xii) Determine the actual number of trays required in tray lower or height of
packing required in packed tower.
(xiii) Determine the actual total pressure drop.
(xiv) Design the condenser, reboiler, etc.

Example 8.15
1000 kg of feed, containing 40% by mass methanol and balance water, is to be separated
in batch distillation with a rectification column. Top product must contain 99.9 % by
mass of methanol. Composition of distillate should remain constant throughout the batch
distillation. Desired composition of residue is 95% by mass water, (a) Design the recti-
fication column (b) Determine the operating (actual) reflux ratio vs time data.
Operating pressure in rectification column is atmospheric.

Table 8.40 Equilibrium Data for Methanol-Water System at 101.3 kPa

Temperature, "C X y
100.0 0.0 0.0
96.4 0.02 0.134
93.5 0.04 0.230
91.2 0.06 0.304
89.3 0.08 0.365
87.7 0.100 0.418
84.4 0.150 0.517
81.7 0.200 0.579
78.0 0.300 0.665
75.3 0.400 0.729
73.1 0.500 0.779
71.2 0.600 0.825
69.3 0.700 0.870
67.5 0.800 0.915
66.0 0.900 0.958
65.0 0.950 0.979
64.5 1.000 1.000

(Table 13-1 of Ref. 14)

Process Engineering Channel

Solution:
Basis: 1000 kg feed consisting 40% methanol (by mass)

0.4x1000 0.6x1000
Feed, F= + = 45.833 kmol
32 18
Mole fraction of methanol in feed,
@ProcessEng

(400/32)
x. = = 0.2727
45.833
Mole fraction of methanol in distillate,

(99.9/32)
xD = = 0.9982
1
(99.9/32)+ (0.1/18)
 Introduction to Process Engineering and Design

Mole fraction of methanol in residue,

(5/32)
xB = = 0.028 75
(5/32)+ (95/18)

F (XF -Xn)
D=F-B= — (8.107)
ixD-xB)

45.833(0.2727-0.02875)
(0.9982-0.028 75)
= 11.5333 kmol
B = 45.833 - 11.5333 = 34.2997 kmol
Draw the equilibrium curve and find the minimum reflux ratio, Rm.
(L/V )min j

yo - ypi
where, (L/V)min = _ (8.103)
X
D xpi
Figure 8.27 shows equilibrium curve for methanol - water system at 101.325 kPa.
x
D= yD = 0.9982
xpi=xF= 0.2127
Corresponding equilibrium value of y
=
ypi )'(af) = 0.6415
0.9982-0.6415
{L/V)min = =0.491 66
0.9982-0.2727

0.49166
Rm = = 0.9672
1-0.49166
Let the reflux ration R at the starting of batch distillation (at 0 = 0) is equal to 2Rm.
R{ =2x0.9672= 1.9344
Slope of operating line
Process Engineering Channel

R\
L/V = —— = 0.6592
R] +1
Intercept of this operating line
V(^i + 1) = 0.9982/2.9344 = 0.34
Figure 8.27 shows that for R[ = 1.9344 it is not possible to get the bottom composition
of xB = 0.028 75. Hence it is planned to increase the reflux ratio gradually from
@ProcessEng

R] = 1.9344 to R9 = 9.
X
D
For reflux ratio R9 = 9 and intercept =0.1, approximately 10 number of theo-
Rg + I
retical stages required to getxB = 0.028 75 as shown in Fig. 8.27. Based on this the value
of number of theoretical stages N = 10 is fixed for all values of reflux ratio. For each
value of reflux ratio, value of bottom composition xwi is determined for /V = 10.
 Process Design of Distillation Columns

'A'

p= 101.325 kPa

(0.2727. 0.6415)
7

y 0.5 1.0

0.4

CD—►
0.3 y 0.95

(D*-
Z 7
jn 7 Detail-A
0^
0.9
0.9 0.95
dr

04 0.2 ^<(1.3 OA 05 06 OT 08 09 yT.O

XB = 0.028 75 -^F = 0.2727 XD = 0.9982

X
D
Point on y-axis R X
B
R+l

© 1.9344 0.3400 0.6354

© 3.0 0.249 55 0.2296
© 3.5 0.2218 0.1427
@ 4.0 0.2000 0.1036
© 4.5 0.1815 0.0774
Process Engineering Channel

5.0 0.1664 0.0616

© 6.0 0.1426 0.0447
8.0 0.1109 0.0294
9.0 0.1000 0.0288

Fig. 8.27 McCabe-Thiele Diagram for Batch Rectification of Methanol-Water Solution.

@ProcessEng

Time required for batch distillation and with constant overhead composition is given
by Bogart equation

^ (8.104)
2
^ x Ul-L/V)(x D-xw)
 486 Introduction to Process Engineering and Design

Table 8.41 Batch Rectification Data

xD 1
R L/V *»■
R+l il-L/V){xD-xw)2

ft, = 1.9344 0.6592 0.34 0.6354

R2 = 3 0.75 0.249 55 0.2727 7.6 (At 0 = 0)
R2 = 3 0.75 0.249 55 0.2296 6.77
/?, = 3.5 0.7778 0.2218 0.1427 6.15
7*4 = 4 0.8 0.2 0.1036 6.25
L»i

0.8182 0.1815 0.0774 6.49

il

Rb = 5 0.8333 0.1664 0.0616 6.84

R-j = 6 0.8571 0.1426 0.0447 7.7
R8 = S 0.8889 0.1109 0.0294 9.59
RQ = 9 0.9 0.1 0.028 75 10.64

Note: Table 8.41 shows that for = 1.9344 and 79= 10, xw = 0.6354 > xF. It means that
for Rl = 1.9344, more than 10 number of equilibrium stages are required to get the
desired separation. In actual operation for R = 1.9344 and TV = 10, distillate composi-
tion obtained will be less than xD even at the starting of batch distillation. It is calcu-
lated to be 0.9917 from the graph (not shown in Fig. 8.27). For R2 = 3 and N = 10,
xw = 0.2296 < xF. Hence it is decided to keep 7? = 3 at the starting of batch distillation.
Total time required
a2 27
45.833(0.9982-0.2727) I dxw
d=
V
0.02875 (I -L/V ) (XD -Xw)2

Draw the graph of ? vs xw and find the area under the curve.
(1 - L/V ){xD- xw)2
From Fig. 8.28, area under the curve from xw = 0.028 75 to xw = 0.2727 is equal to
1.637 47.

45.833(0.9982-0.2727)
0= x 1.637 47
V
VO = 54.449 kmol
Process Engineering Channel

154 :449
If the total time of batch distillation is fixed at 0=6 h,. then V = —
6
V = 9.0748 kmol/h
Total time for batch distillation in any batch process is fixed based on the time re-
quired by the equipment which is governed by the batch process. In most of the cases
time required by the reaction in batch reactor decides the time of batch process and time
of other separation operations like batch distillation.
@ProcessEng

Total distillation time, 0 = 6 h

Here reflux ratio R at the starting of batch distillation is 3. In operation R can be kept
equal to 3 from 0=0 to 0= 9^.

Area of segment from xw = xF to xw = 0.2296

0i = x0
Total area under the curve
 Process Design of Distillation Columns 487

11.0

10.0

9.0 \

\
8.0
\ ©
7.0 \

Q 6.0
H

-1 5.0

4.0

3.0

2.0

1.0

0
0 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16 0.18 0.20 0.22 0.24 0.26 0.28
x
w
Fig. 8.28 Evaluation of Integral for Batch Distillation

_a3062_ )<6 = ] 122h

1.637 47
For R3 = 3.5, area of segment from xw = 0.2296 to xw = 0.1427 is 0.558 89
(determined from Fig. 8.28)

0.55889
Hence, 6, = x 6 = 2.048 h
" 1.637 47
Similarly,

0.242 43
For /C=4, 03 = x6 = 0.8883 h
1.637 47
Process Engineering Channel

0.150 34
For R5 = 4.5, 04 = — x 6 = 0.5509 h
1.637 47

0.12241
For *6 = 5, ft = x 6 = 0.4485 h
1.637 47
@ProcessEng

0.12194
For R7 = 6, ft = x 6 = 0.4468 h
1.637 47

0.12901
For /?o = 8, ft = x 6 = 0.473 h
1.637 47
 488 Introduction to Process Engineering and Design

0.00613
For R9 =9, d9 = | ^ x 6 = 0.0225 h

Table 8.42 Ref/ux Ratio vs Time

R e Av
3 0 to 1.122 0.2727 to 0.2296
3.5 1.122 to 3.17 0.2296 to 0.1427
4 3.17 to 4.0583 0.1427 to 0.1036
4.5 4.0583 to 4.6092 0.1036 to 0.0774
5 4.6092 to 5.0577 0.0774 to 0.0616
6 5.0577 to 5.5045 0.0616 to 0.0447
8 5.5045 to 5.9775 0.0447 to 0.0294
9 5.9775 to 6 0.0294 to 0.028 75

Design of distillation column:

Type of tower = Packed tower (small capacity)
Type of packing = Stainless Steel Pall rings
Size of packing = 16 mm
% void space = 92%
Packing factor Fp = 230 irT1 (Table 9.2)
Tower diameter required at bottom:

K PG V
^G = (9.15)
Gw PL

Molar flow rate of vapour. V = 9.0748 kmol/h

V = L + D and UD = R
Maximum value of actual or operating reflux ratio in the entire operation is 9.

Anax = ^max D = 9 D
V = L + D = 9D + D = 10 D

D = — = 0.907 48 kmol/h
10
Process Engineering Channel

L = 8.1673 kmol/h
Composition and average molar mass of vapour and liquid phases at bottom are chang-
ing with time. Average molar mass is maximum at the starting of distillation.
At the starting of distillation
Mav = 0.2727 x 32 + (1 - 0.2727) x 18 = 21.8178 kg/kmol
@ProcessEng

L x Mav l{-^\ D2
^-= ^ = ±=0.9
Gw /TT)^2 V
V*Maj[±)D

Bubble point temperature at x = 0.2727 is 790C (from t-xy data)

 Process Design of Distillation Columns

pMa 101.325x21.8178
Pg = = 0.7554 kg/m3
RT 8.314 x (273+ 79)

1 _.
— .( 0.4 0.6
Pi = '
W:- \1753 972.42
I—
Pu

p, =870.9 kg/m3

Q 7554
F = 0.91 - > = 0.0265
1
870.9 J

From Fig. 9.3,KF = 0.2

Let actual velocity of vapour through packed tower = 70 % of flooding velocity

K
x 1000 = 70
KF

K = (0.70)2 Kf = 0.098
Corresponding Ap = 83.3 mm WC/m of packing (From Fig. 9.3)

I
k
PgPlS
G„.= (9.18)

K = 0.098, pG = 0.7554 kg/m3, pL = 870.9 kg/m3

130 m"
Fp = 230 m-'

Density of water 972.42

4^ =
Density of liquid 870.9

4^ = 1.1166
pL = viscosity of liquid solution
Viscosity of 40% methanol solution (by mass) at 79° C,
Process Engineering Channel

pL = 0.45 cP = 0.45 mPa • s

(Fig. 3.43, of Ref. 14)

0.098x0.7554x870.9x9.81
G,„ =
230x1.1166 x 0.45 0-2

= 1.7 kg/(m2 • s)
@ProcessEng

Mass flow rate of vapour, mv = 9.0748 x 21.8178 = 198 kg/h = 0.055 kg/s

Area required at bottom = = 0.032 35 m2

1.7
 490 Introduction to Process Engineering and Design

A =0.032 35 = | -)£>;

Di = 0.203 m
Tower diameter required at top

U Pg_
Flg = (9.15)
Gw PL

Lw
= 0.9
V

Mav = 0.9982 x 32 + (1 - 0.9982) x 18 = 31.9748 kg/kmol

101.325x31.9748
Pc = = 1.1546 kg/m3
RT 8.314 x (273+ 64.5)

Top temperature is the dew point temperature of overhead vapour. It can be deter-
mined from t-x-y data. Find the value of t for y = xD = 0.9982
pL = Density of methanol at 64.5 0C = 760 kg/m3

,1/2
1.1546
Flg = 0-9 = 0.035
760 J
From Fig. 9.3,^ = 0.18
Let actual velocity of vapour is equal to 70% of flooding velocity.
K = (0.7)2 Kf = 0.0882
Corresponding Ap = 90 mm WC/m of packing

i
X
l2
K Pg PI. 8
G. = (9.18)
F^Pl2

Density of water 980.827

Process Engineering Channel

V
F= = 1.29
Density of liquid 760

(Density of water is from Table 3.28, of Ref. 14)

fiL = Viscosity of methanol at 64.50C = 0.34 cP = 0.34 mPa • s

\ —I
0.0882x1.1546x760x9.81
G,„ =
@ProcessEng

v 230 x 1.29 x0.34,0.2

L
s

Gw = 1.7819 kg/(m2 ■ s)
Mass flow rate of vapour, mv = 9.0748 x 31.9748 = 290.165 kg/h = 0.0806 kg/s
 Process Design of Distillation Columns

Area required at top = = 0.045 23 m2

1.7819

4 x 0.04523
D=
i —-— =0-24m

Take D, = 0.24 m for the entire tower.

HETP (height equivalent theoretical plate) for Pall rings = 0.5 m
Total height of packing = HETP xN = 0.5 x 10 = 5 m
Let the total height of packing = 5.1 m
Number of packing sections = 3 each with 1.7 m packed height
Type of liquid distributor = Pipe type
Number of holes required in pipe type reflux distributor.

(7r/4) D,2 x 104

"h =
194
For each 30 in" (194 cm") area, one distribution point is required.

(7r/4) (0.24)2 x 104

nh = = 2.33
194
Let nh = 4

Liquid

4 No. 3.5 0 Holes

Process Engineering Channel

5 mm ID Pipe
@ProcessEng

0= 120 mm

Fig. 8.29 Pipe Type Liquid Distributor

 Introduction to Process Engineering and Design

Let the velocity of methanol through pipe = 2 in/s

Volumetric flow rate of reflux

LM.m (0.9 x 9.0748) x 31.9748

p, x 3600 760 x 3600

= 9.545 x lO"5 m3/s

Inside diameter of pipe:

9.545 x 10_5 x 4
d: = = 0.007 79 m
]l 2X71

Let d; = 8 mm
Let the velocity of solvent through holes = 3 m/s
Let d,, = diameter of hole, mm

ir . 9.545 xl O-5
4 x -d} = = 3.181 67 x l(r5
4 h 3
dh = 0.0032 m
Let dh = 3.5 mm
Packing Support:
Packing support should be selected such that flow area provided by packing support for
the flow of gas should be greater than flow area provided by packing material.
% void space for 16 mm size SS Pall rings = 92 % (Table 9.2)
Hence with Pall rings, any gas-injection type packing support must be used. Let the
type of packing support is cap type packing support.
Actual outer diameter of packing support is greater than 240 mm as some portion of
packing support is sandwiched between two flanges.
Let h = Height of slot in riser, mm
a = Width of slot in riser, mm
d,. = Diameter of riser, mm
n = Number of risers, mm
D( = Inside diameter of column, mm

Let d.. = = 40 mm
6
Number of risers, n = 9
Process Engineering Channel

Let ns = number of slots per riser

Total area of slots of risers = ns n h a where, distance between two successive slots is
a mm.
Let a = 5 mm
nd: 7rx40
n = = = 12.566
2a 2x5
@ProcessEng

Let ns = 12

Hence, total area of slots of risers = 12x9x/7x5> 0.92 x — (240)2

4
h > 77 mm
Let h = 80 mm
 Process Design of Distillation Columns

= 240

0 = 40mm

Weep Holes

t
80 100

Section XX
Fig. 8.30 Cap Type Packing Support

8.6 SHORT PATH DISTILLATION21 22

Short path distillation is very high vacuum distillation. Operating pressure at

distillation surface in short path distillation unit (SPDU) is as low as I0~6 bar
(I pbar). Short path distillation provides the distillation at the minimum possible
temperature which is desirable for heat sensitive products.
In distillation, maximum boiling point is of the bottom product. If the normal
boiling point of any product of distillation is higher than the decomposition tem-
perature or cracking temperature, distillation cannot be carried out at atmospheric
pressure. Reduction in absolute pressure results in the reduction in distillation
temperature or boiling temperature. In lower pressure range, more reduction in
Process Engineering Channel

boiling temperature of pure component is observed for a small reduction in oper-

ating pressure. For example, boiling point of stearic acid is reduced by 0.2oC
when operating pressure is reduced from 251 mbar to 250 mbar. But, its boiling
point is reduced by 3.80C when operating pressure is reduced from 5 mbar to 4
mbar. In both cases, reduction in operating pressure is 1 mbar but in lower pres-
sure range reduction in boiling point is quite higher. Hence, reduction of pressure
@ProcessEng

in lower pressure range is important as it creates considerable reduction in boil-

ing point. For a food grade product (example: orange juice) and for a highly heat
sensitive product (example: vitamin E, i.e. oc-tocopherol) reduction in boiling
point means better recovery. Maximum recovery is obtained at the minimum boil-
ing temperature.
 Introduction to Process Engineering and Design

Decreases in pressure results in the increase of vapour volume per unit mass
and in turn it results in increase in vapour velocity. In the lower pressure range,
even low vapour flow rate or non-condensable flow rate results in relatively higher
value of pressure drop.
It will be interesting to note change in properties of ice and water vapour from
Table 8.43 at low, high and ultra high vacuum.

Table 8.43 Properties of Water. Ice and Water Vapour at Low Temperatures23

Melting Saturation Density Specific volume Specific enthalpy,

point vapour of of saturated kJ/kg
T t pressure, p ice, p. vapour, V
o
K c Pa bar kg/m3 m3/kg Ice Sublimation Vapour
273.15 0 611.65 0.611 x lO"2 916.708 205.99 -333.4 2834.3 2500.9
270 -3.15 470.06 0.470 x lO"2 917.170 264.96 -340.0 2835.1 2495.1
265 -8.15 305.92 0.306 x lO"2 917.886 399.64 -350.2 2836.2 2486.0
-2
260 -13.15 195.81 0.196 x lO 918.594 612.65 -360.3 2837.1 2476.8
255 -18.15 123.15 0.123 x K)"2 919.295 955.48 -370.2 2837.8 2467.6
250 -23.15 76.02 0.760 x lO"3 919.980 1517.5 -380.0 2838.3 2458.3
3
245 -28.15 46.01 0.460 x lO" 920.658 2457.3 -389.5 2838.6 2449.1
240 -33.15 27.27 0.273 x lO"3 921.319 4061.4 -398.9 2838.7 2439.8
235 -38.15 15.81 0.158 x K)"3 921.973 6860.7 -408.0 2838.6 2430.6
230 -43.15 8.95 0.895 x 10 4 922.611 11861 -417.0 2838.4 2421.4
225 -48.15 4.94 0.494 x lO"4 923.233 21021 -425.9 2838.0 2412.1
220 -53.15 2.65 0.265 x lO"4 923.839 38249 -434.5 2837.3 2402.8
215 -58.15 1.39 0.139 x 10"4 924.437 71588 -443.0 2836.6 2393.6
210 -63.15 0.702 0.702 x lO"5 925.018 1.3809 x 105 -451.3 2835.6 2384.3
205 -68.15 0.344 0.344 x HP5 925.583 2.7514 x 105 -459.4 2834.4 2375.0
200 -73.15 0.1626 1.626 x lO"6 926.132 5.6759 x 105 -467.3 2833.1 2365.8
6
195 -78.15 0.7404 0.740 x lO" 926.655 1.2155 x 106 -475.1 2831.6 2356.5

Reference State:
Specific enthalpy of saturated liquid water at 273.16 K (O.OPC) = 0 kJ/kg

Specific volume of saturated water vapour at 0.1 bar (boiling point = 45.83
0
C), 1.232 x lO-3 bar (or 1.232 mbar) and 1.626 x lO"6 bar (or 1.626 pbar) is
Process Engineering Channel

14.675 m3/kg, 955.48 m3/kg and 5.6759 x 105m3/kg, respectively. Thus several
fold increase in vapour volume will have to be handled at ultra high vacuum.
This will call for big size pipes (ducts) for transporting vapours at ultra high
vacuum so that low pressure drops are achieved.
Hence, in all vacuum distillation columns, minimum possible value of absolute
pressure at vaporization surface of boiling liquid in reboiler is decided by pressure
@ProcessEng

drop of vapour flowing from vaporization surface of liquid in reboiler to the heat
transfer surface of external condenser. In conventional packed tower type vacuum
distillation column, vapour travel a long path from reboiler to external condenser.
Also, in conventional design, no extra care is generally taken to reduce the flow
of non-condensables.
 Process Design of Distillation Columns

To break this physical barrier of pressure drop of vapour and non-condensables

travelling very long path from vaporizing surface to external condenser, in short
path distillation, an internal condenser is used and because of the same, vapour
travels through a very short distance, in order of few centimetres, from vaporiza-
tion surface of liquid of bottom product to the surface of internal condenser.
Because of the shortening of the path length of vapour and non-condensables,
this new unit is known as short path distillation unit (SPDU).
There is a confusion in between the words "Molecular Distillation" and "Short
Path Distillation". In the latter, if the distance travelled by vapour molecules from
the vaporization surface to the surface of internal condenser is less than mean
free path of molecules between two successive collisions, then short path distilla-
tion is called molecular distillation. If in this path length, there is no collision
between vapour molecules then pressure drop in vapour flow is the minimum.
Decrease in pressure increases the mean free path of molecules between two
successive collisions. For commercial applications, it is not necessary to achieve
the condition of molecular distillation for each application, hence only a few
short path distillation units are operated as molecular distillation.

8.6.1 Design and Working of Short Path Distillation Unit

A short path distillation unit consists of a vertically mounted double walled vacuum
chamber with a central inner condenser and roller wiper system.

5
4
Process Engineering Channel

3 1 Residue Discharge
10 2 Heater Jacket
3 Roller-Wiper System
4 Space Under Vacuum
5 Internal Condenser
6 Feed
7 Geared Motor
8 Shaft with Feed Distributor Plate
@ProcessEng

9 Heating Medium Outlet

10 Heating Medium Inlet
11 Exhaust to Vacuum System
12 Cooling Medium Outlet
14 12 13 Distillate Discharge
14 Cooling Medium Inlet
Fig. 8.31 Typical Short Path Distillation Unit
 Introduction to Process Engineering and Design

Feed is continuously fed on a rotating distributor plate. At the bottom of rotat-

ing distribution plate, 3 to 12 guiding rods are mounted. These guiding rods
contain the rollers which are passed over the rods. Distribution plate with rods
and rollers is rotated by an electric motor. This entire rotating system is known as
Roller-Wiper system. Feed material is thrown by rotating distributor to wall or to
heat transfer surface. Then material flows down by gravity over the heat transfer
surface. Rollers do not touch the heat transfer surface but they create the pressure
and turbulence in liquid film. Rollers are rotated about the central axis of the unit
and are also rotated about their own axis. Friction between liquid film and rollers
create the automatic rotation in rollers about their own axis. This roller wiper
system creates effectively mixed, uniform and thin film over the heating surface.
Heating is provided by thermic fluid, saturated steam or hot water. Liquid film is
partially vaporized. Vapour travel through the shortest path from liquid film sur-
face to the surface of inner central condenser. Cooling medium may be cooling
water, chilled water, oil or brine.
Residue and condensate (distillate) both are falling down by gravity. Partition
is provided to avoid the possibility of the mixing of residue and distillate.
Vacuum nozzle located at the side bottom of vessel, through which
noncondensables and some vapours are drawn out by vacuum system. Vapours
are condensed in a cold trap. Vacuum measuring instrument is also provided in
the bottom part.
Unit is kept in the perfect vertical position and hence residence time of liquid
on the heating surface is in the order of few seconds. The distillation takes place
in "single pass" or in "once through". In this operation, in the short residence
time and the lowest, vaporization temperature reduces the possibility of thermal
degradation of product. Thus SPDU provides the most gentle conditions for the
distillation of heat sensitive products.
Sometimes it is advisable to have a degassing stage in front of short path
distillation unit, to remove the dissolved noncondensable gases like oxygen, ni-
trogen, etc. In addition to this maximum tightness of the system, the prevention
of gaseous cracked products and the lack of stripping gas reduce size of vacuum
system required and also reduces the operating cost of the vacuum system.
Standard short path distillation units with heating surface area range from
Process Engineering Channel

0.01 m2 to 42 m2, heating temperature up to 450oC and product throughput range

from a few g/h to several t/h are available.

8.6.2 Applications of SPDU2122

The use of short path distillation to modify the traditional processes or for the
development of a new process requires special knowledge because many classi-
cal rules and laws of traditional vacuum distillation cannot apply to short path
@ProcessEng

distillation. Recognized suppliers of short path distillation unit provide this knowl-
edge to customers by their engineering services. They provide the facility of a
trial run for the new system in their pilot units.
Short path distillation finds its application in pharmaceutical industries, fine
chemicals industry, polymer industries, food industries, oil industries and refin-
eries. Some important applications are:
 Process Design of Distillation Columns

(a) Separation of Vitamin E: The short path distillation is applied for syntheti-
cally produced vitamin - E as well as for natural vitamin - E. The synthesized
vitamin - E exists in the final stage as acetic acid ester (as vitamin E - acetate).
About 100 kg crude vitamin - E acetate contains 78.75 kg pure vitamin - E
acetate, 13.75 kg residue and 7.5 kg low boiling impurities (typical data). In two
stage short path distillation, pure vitamin E acetate is obtained as light yellow
pure oil.

Crude
vitamin E
acetate
Degassing K SPDU-I
tower 0.2 mbar
0.2 mbar 1970C

Residue

Low boiling
Impurities

SPDU-II
0.006 mbar
205oC
To vacuum
r system
Residue through a
cold trap
Pure vitamin E acetate

Fig. 8.32 Distillation ofVitamin-E Acetate

Process Engineering Channel

Deodorizer distillate of an edible oil refinery is a source of natural vitamin - E.

Its concentration varies from 3 to 10% (by mass) in the distillate of soybean oil,
depending on the operating conditions of the deodorizer. Concentration upto 40%
(by mass) can be carried out in SPDU.
(b) Separation of Monoglyceride:
Monoglycerides are mono fatty acid esters of glycerol.
@ProcessEng

Mono fatty acid + Glycerol —> Monoglyceride + Water

Monoglycerides are used as emulsifiers in many of food products. The mod-
ern food product technology demands the concentration of monoglyceride more
than 90%. It is a heat sensitive product. More than 90% concentration of
monoglycerides is achieved by two stage short path distillation.
 Introduction to Process Engineering and Design

[->-70 vacuum system

CW To vacuum system

To vacuum
system through
Water a cold trap
iMl
Mono fatty fcid
+ glycerol

SI'DIJ Sl'DU
0.4 mbar 0.007 mbar
Reactor 194 C 207 C
40 mbar Triglyceride
245°C
Dcgasscr
2 mbar
0
> 90% Monoglyceride
Recycle 167 C

Fig. 8.33 Manufacturing of Monoglyceride

(c) Carotene: It is a pro-vitamin which is used as a supplement in many food

products. Red palmoil ester contains about 0.06% carotene. Three stage short
path distillation plant is required to increase the concentration upto 40%.

Palm oil ester

with 600 mg/L
/J-Carotene
To vacuum
SPDU-I SPDU-I1 SPDU-lIi system through
0.1 mbar 0.08 mbar 0.05 mbar a cold trap
-w I95°C ->■/ 190oC 180°C "t ►-

40%
/3-Carotene
Process Engineering Channel

Ester (Distilate) Ester (Distilate) Ester (Distilate)

0.5 mbar 180oC
Fig. 8.34 Manufacturing of Cartone

(d) Dimeric Fatty Acids: They are basic materials for polyester or alkyd resins.
They are produced by dimerisation of oleic acid. After reaction a mixture of
monomer, dimer and oligomer fatty acids are formed. The fractionation of this
@ProcessEng

mixture takes place in two or there stage short path distillation plant.
(e) To recover more middle distillate from the residuum, coming from vacuum
distillation unit of refinery, currently vacuum distillation is carried out in
conventional distillation equipment in which operating pressure at the base of
column or in reboiler is decided by pressure drop in the column. The same
operating pressure also decides the certain boiling range of residuum. Currently,
 Process Design of Distillation Columns 499

Crude oligomer
with 15% monomer

Degasser
10 mbar ll
80oC

SPDU-I SPDU-II
0.2 mbar 0.03 mbar
130oC 140oC Residue

o
S
(D
T35
' Distillate v Oligomer
<0.1%
SPDU-III monomer
3 mbar
110oC

To vacuum system
through a cold trap

Monomer
Fig. 8.35 Manufacturing of Dimeric Fatty Acids

considerable amount of middle distillate remains in the residuum. With

conventional vacuum distillation unit, one can increase the % recovery of middle
distillate by increasing base temperature but the same cannot be permitted because
increase in the base temperature above the certain limiting value results in
considerable thermal cracking of the residuum. In short path distillation the same
residuum can be boiled or distilled at much lower temperature range. Reduction
in operating pressure in SPDU creates the sizeable reduction in boiling
Process Engineering Channel

temperatures. Hence with SPDU, it is possible to recover the middle distillate

further without causing thermal cracking.
(f) Oleoresin: Oleoresin is a red colour natural pigment separated from paprika.
It is used as a natural colour additive in food products. The oleoresin is extracted
by hexane. From the extracted product, which contains 96% oleoresins and 4%
hexane (by mass), hexane can be completely removed from oleoresin (down to
10 ppm) by two stage short path distillation.
@ProcessEng

(g) Deacidillcation of Ricebran Oil and Palm Oil: Ricebran oil and palm oil,
are preferred to be used as cooking mediums because of their high nutritional
values. But because of considerable high content of free fatty acids, deacidifica-
tion by conventional distillation is difficult. With short path distillation, these
oils can be gently deacidified to the concentrations of less than 0.1 % without loss
of nutritional values.
 Introduction to Process Engineering and Design

To vacuum
> > >- system through
96 % Oleoresin a cold trap
+
4 % Hexane 1 0 0

1 1
Degasser
3 mbar >
80oC
SPDU-I SPDU-II
0.4 mbar 0.01 mbar
105oC 1220C
Oleoresin

Distillate Distillate
(Hexane) (Hexane)
Fig. 8.36 Separation of Oleoresin

(h) Separation of Monomers from Prepolymers: Polyurethanes are polymers

with different compositions and wide range of characteristics. They are produced
by polyadduct type polycondensation reaction from toluene diisocyanate and
polyols. In the first step, so called prepolymers are formed. These prepolymers
still contain a certain amount of non-reacted diisocyanate monomers. It is neces-
sary to reduce monomer content before selling to end manutactures because these
monomers are toxic in nature. It can be reduced by short path distillation.

8.6.3 Economics

It is a general impression that cost of short path distillation unit is quite high. The
reason for this is historical. The first industrial short path distillation plants were
operated with very low throughputs to maintain the very low value of operating
pressure at distillation surface. Vacuum technology was not advanced at that time
and this was the limiting factor for the throughput. Also in initial stages there
Process Engineering Channel

were high over dimensioning of the unit. These all reasons created the general
impression that short path distillation is very expensive operation and the
distillation cost can only be borne by very expensive products. But now, reality is
different.
Improved vacuum technology, considerately higher throughput quantities, in-
creased availability of units from different manufacturers and low personnel re-
@ProcessEng

quirements have led to a substantial reduction in cost of distillation. Results have

shown that on increasing product throughput from 150 kg/h to 3600 kg/h, total
cost of short path distillation in Rs./kg of product reduces by more than 85%.
Short path distillation unit requires only one week shut down lime per year.
Hence it requires relatively less maintenance.
 Process Design of Distillation Columns 501

8.7 REACTIVE AND CATALYTIC DISTILLATION24 25

In most of the chemical plants one can find the reaction followed by separation.
Usually reaction and separation are performed one by one. First reactants are
allowed to react in the reactor, then in a separate equipment product mixture is
separated from unconverted reactants and/or from byproducts and inerts. It is
rarely seen that both reaction and separation combined and carried out simulta-
neously in one equipment.
However, by combining reaction and separation of product in one equipment
one can get two advantages.
1. Removal of the product from the reaction mass at the reaction conditions
increases equilibrium conversion of reactant or increases the extent of re-
action. As per LeChatelier's law, for the reaction in equilibrium, if any
change in any process variable like pressure, temperature or composition
of reaction mass is made, reaction or process is moved in such a direction
which will nullify the effect of the change in the variable. In reactive distil-
lation, change in the composition of reaction mass is made by continuously
removing the product from the reacting mass. Hence, to nullify the effect of
this change, reaction proceeds in the forward direction and produces more
and more products and so equilibrium conversion is improved.
2. Separate equipment for the separation is not required. Also separate piping,
instruments, etc. are not required.
There are four commonly used techniques to combine reaction and
separation.
(i) Reactive distillation (Reaction + Distillation )
(ii) Membrane reaction (Reaction + Membrane separation )
(iii) Extractive reaction (Reaction + Extraction )
(iv) Reaction with absorption ( Reaction + Absorption)
In reactive distillation, reaction and distillation both are carried out simultane-
ously in one equipment. If reactive distillation is carried out in presence of
heterogeneous solid catalyst, then it is called catalytic distillation.
The concept of reactive distillation is not new. This technique was first ap-
Process Engineering Channel

plied in 1920 to esterification process using homogeneous liquid phase catalyst.

In manufacturing of ethyl acetate, reaction between ethanol and acetic acid and
separation of crude ethyl acetate from reaction mass by distillation were carried
out simultaneously in one equipment. Ethanol was used as excess reactant. Over-
head vapour from reactive distillation column is a ternary azeotrope having com-
position 82.16% ethylacetate, 8.4% ethanol and 9% water (by mass). On conden-
@ProcessEng

sation heteroazeotrope vapour is converted in to two layers, ester rich layer and
ethanol-water solution layer. Part of ester rich layer is taken out as top product
(distillate) and remaining is recycled back to column as reflux. Sulphuric acid is
added in feed as catalyst. Waste water (water + sulphuric acid) is continuously
taken out as bottom product. Alcohol - water stream is taken out as an intermedi-
ate product.
 502 Introduction to Process Engineering and Design

In manufacturing of butyl acetate over head vapour is a ternary hetroazeotrope

of butyl acetate, butanol and water. On condensation it is converted into two
immiscible liquid layers.

Table 8.44 Ternary Azeotrope Separation at 90oC

Layer % by mass % Ester % Butanol % Water

Upper 75 80.5 13.4 6.1
Lower 25 1.92 1.69 97.39
(Table 12.7 ofRef. 26)

Lower aqueons layer is continuously taken out from decanter for recovery of
butanol (separately) while upper layer or ester rich layer is recycled back to col-
umn as a source of reflux. Bottom product is crude butyl acetate. It is sent for
further purification. Thus in both cases, concept of reactive distillation, invented
in 1920, was applied. But after that for a long period of time very little work was
done in this direction. Almost after 50 years, an important research work was
97
done by Sermewald in 1971^ , that applying reactive distillation with heteroge-
neous catalyst is far more useful than homogeneous catalyst. Nowadays, this
technique is being successfully applied to some processes like synthesis of me-
thyl tertiary butyl ether (MTBE), synthesis of ethyl tertiary butyl ether (ETBE),
selective hydrogenation of butadine of C4 stream, synthesis of ethyl propionate,
methyl acetate, etc.
If solid catayst is used, then the same catalyst can also act as packing material
of packed tower. In that case solid catalyst plays double role to enhance the rate
of chemical reaction as well as to enhance the rate of mass transfer for distilla-
tion. This special type of reactive distillation which uses solid catalyst is known
as catalytic distillation.
Even though reactive distillation has two major advantages over conventional
reactor followed by distillation (as mentioned earlier in this chapter), it finds its
place only in few processes. Reason is, it also has one major disadvantage.
Disadvantage:
In majority of the processes which involve reaction followed by distillation,
Process Engineering Channel

optimum conditions for reaction and optimum conditions for distillation are
different. Hence to carry out both symultaneously in one equipment, one has to
compromise in reaction or distillation. In most of the cases, the compromise is in
the distillation. In a few cases like in the process of MTBE, optimum conditions
for the reaction and the same for distillation are more or less same. Hence one
can apply the concept of catalytic distillation in the process of MTBE. But in
many cases this combination is not economically feasible. For example: in the
@ProcessEng

manufacturing process of acetic acid by carbonylation of methanol, first reaction

is carried out in presence of homogeneous phase catalyst at 50 atm pressure and
at 180oC temperature. After the reaction, reactants, promoters and catalyst are
separated from acetic acid by distillation at atmospheric or near to atmospheric
pressure. Hence in this case one cannot apply the concept of reactive distillation
because optimum conditions for the reaction and for the distillation are very much
different.
 Process Design of Distillation Columns

8.7.1 Comparison of Reactive Distillation with

Conventional Technology

Conventional technology involves two steps.

Recycle Stream

CW

Reactants
+
Reactor
Inert
Reactants
+
+
Catalyst
Inert U
+ Recovery Unit
Catalyst

Product

Fig. 8.37 Typical Conventional Process

In the conventional process first step is the reaction step. In this step reactants
are brought into contact with solid or liquid catalyst at appropriate temperature
and pressure.
In second step stream from the reactor is sent to separation section, where
desired product is separated from unconverted reactants, catalyst, byproducts and/
Process Engineering Channel

or inerts. In most of the cases this separation is done by distillation.

When concept of reactive distillation (or catalytic distillation, if catalyst is in
solid phase) is applied to such type of processes, flow sheet is changed. Typical
flow sheet of catalytic distillation column is shown in Fig. 8.38.
In middle section of catalytic distillation column, reaction and distillation take
place simultaneously while upper and lower sections represent enriching and
stripping sections of distillation or they are utilized only for separation.
@ProcessEng

The advantages of reactive distillation can be described best by considering

its advantages over reaction step and distillation step of conventional process,
(a) Advantages over Reaction Step:
(i) For equilibrium limiting reaction, continuous removal of one of the prod-
ucts at process conditions increases equilibrium conversion and it converts
 Introduction to Process Engineering and Design

CW
Inert +
Very Less
c
.0 Amount of
E *—
a 2 Reactant
o C3
■fa CLV
_o •4—'
o t- (D
>.
o
o i- •Rectification Zone
a: > 0)

Reactive Distillation
Reactants
+ Zone with Catalyst
Inert

Stripping Zone

Product
Fig. 8.38 Typical Flow Sheet of Catalytic Distillation

reversible reaction into irreversible reaction. Thus reactive distillation pro-

vides high conversion compared to conventional reaction step.
(ii) For exothermic or endothermic reaction, separate cooling or heating sys-
tem is required for reactor in conventional process. In reactive distillation,
separate heating or cooling system is not required for reaction zone. In
Process Engineering Channel

reactive distillation, heat of reaction is utilized in distillation either for con-

densation or for boiling.
(b) Advantages Over Distillation Step:
(bi) Advantages Related to Reduction in Capital Cost
(i) In conventional technology, separate equipment is required for distillation.
Reactive distillation eliminates use of major process equipment and associ-
@ProcessEng

ated pump, piping and instrumentation.

(ii) Heat of reaction reduces either condensation duty or reboiling duty. Hence
it either reduces condenser size or reboiler size.
(iii) In reactive distillation very less amount of uncoverted reactants are to be
separated from products compared to distillation in conventional technology.
Hence reactive distillation requires lesser number of stages for same value
 Process Design of Distillation Columns

of reflux or less amount of reflux compared to distillation of conventional

technology or it requires lesser size of distillation column compared to the
same required for the distillation in conventional technology for the given
production rate. Less amount of reflux also decreases sizes of condenser
and reboiler.
(b2) Advantages Related to Reduction in Operating Cost
(i) Heat of reaction reduces either condensation duly or reboiling heat duty.
Hence, it reduces either load of cooling system or the same of heating system.
Consequently, it reduces operating cost.
(ii) Operating cost required for recycling of reactants is reduced considerably.
(iii) In reactive distillation, amount of distillate is reduced considerably. Hence,
for the same reflux ratio, lesser amount of reflux is required in reactive
distillation compared to distillation column of conventional technology. It
decreases condenser heat duty, reboiler heat duty and power required for
pumping the reflux.

8.7.2 Different Ways by Which Reactive Distillation Can

be Applied

There are three different ways by which Reactive Distillation can be applied.
(i) Reactive Distillation alone
(ii) Reactive Distillation plus Non-reactive Distillation.
(iii) Reaction alone plus Reactive Distillation plus Non-reactive Distillation.
(i) Reactive Distillation Alone:
In this case, throughout the whole column, reaction and distillation take place
simultaneously. At one of the ends, purified product is obtained. This is possible
only for the systems for which pure product point lies within reaction space.
(ii) Reactive Distillation plus Nonreactive Distillation:
There are many cases for which pure product point does not lie within reaction
space. For such cases, nonreactive distillation section (either rectifying or strip-
ping or both) is also required to achieve pure product and pure reactants.
(iii) Reaction alone plus Reactive Distillation Plus Non Reactive Distillation
(Optional):
Process Engineering Channel

If the reaction space required is considerably greater than distillation space, then
this method is applied.
Sometimes it is not recommended to shift entire reaction space to reactive
distillation unit. The reason may be one of the followings.
(a) If the optimum reaction conditions and optimum distillation conditions are
different, then it is better to improve only equilibrium conversion in reac-
@ProcessEng

tive distillation, while major part of reaction (up to equilibrium conversion)

can be carried out separately in another reactor.
(b) If the existing plant of conventional technology have more number of reac-
tors in series than one may shift only last or a few of the last reactors to
reactive distillation unit.
 506 Introduction to Process Engineering and Design

8.7.3 Various Contact Devices Used for Catalytic

Distillation

In catalytic distillation, contact devices are required to improve mass transfer rate
and to improve catalyst contact. Various types of contact devices used for cata-
lytic distillation are as follows.
(a) Tray column in which bed of catalyst is placed either in downcomers or
above the trays.
(b) Packed tower using random packing elements which contain the catalyst
(such as special coating) or which may be made of the catalyst.
(c) Packed tower using ordered packing elements which contain catalyst parti-
cles. In orderly packing element, catalyst particles are sandwiched between
two supporting materials. Two types of ordered pickings are used.
(i) Bale packing
(ii) Structured packing
1. Bale Packing:
In bale packing, catalyst particles are enclosed within several pockets in a fiber
glass cloth belt.

Bale
Packing

Enlarged Bale
Flow
Channel

Bale Surrounded
by SS Wire Mesh

Liquid
Process Engineering Channel

Vapour-

Wall Wipers
@ProcessEng

Fig. 8.39 Bale Packing

 Process Design of Distillation Columns 507 |

The pockets are normally 2.5 to 5 cm wide with 0.625 to 1.25 cm web be-
tween them. Open ends of pockets are sewn closed. Belts are rolled up with
alternating layers of stainless steel mesh. Stainless steel mesh increases struc-
tural strength of cloth belt.
Bales constructed for commercial use are roughly cylindrical shape with 20 to
35 cm diameter and 50 cm height. Several bales then packed tightly into a col-
umn such that pockets remain vertical. Flow channels facilitate the contact be-
tween vapour and liquid. Ideally, contact between liquid reactants and catalyst is
taking place in pockets and vapour-liquid contact takes place in flow channel.
HETP as well as pressure drop relations for bale packings could be obtained
from the supplier.
2. Structured packing:
KATMAX structural packing is developed by Koch Engineering Company, USA.
From outside this packing looks like a brick with corrugated surface. In such type
of packing solid catalyst is held in a screen envelope.
The catalyst is sandwiched between the layers of screen. It is easily accessed
by the liquid. Between two layers of catalyst (surrounded by screen), gaps are
provided, known as flow channels which facilitate the flow of vapour. Inside the
flow channel vapour makes the contact with liquid film.

8.7.4 Industrial Applications of Reactive Distillation

(a) Manufacturing of ethylacetate from ethanol

(b) Manufacturing of methylacetate from methanol
(c) Manufacturing of butylacetate from butanol
(d) Manufacturing of MTBE (methyl tertiary butyl ether) and ETBE (ethyl ter-
tiary butyl ether)
(f) Selective hydrogenation of butadine of C4 stream
(g) Selective hydrogenation of pentadine of C5 stream
(h) Selective hydrogenation of hexadine of C6 stream
(i) Manufacturing of benzyl chloride from toluene
(j) In benzene separation of gasoline.
(k) Manufacture of ethyl propionate from ethanol
(1) Manufacture of amino resins
Process Engineering Channel

Among these applications, manufacturing of ETBE by catalytic distillation is

discussed in this chapter.

8.7.5 Manufacturing of ETBE

Ethyl tertiary butyl ether is used as octane number improver, like MTBE. ETBE
has higher octane rating and lower volatility compared to MTBE. However, oxy-
@ProcessEng

gen content of ETBE is less compared to MTBE, hence larger volumes of ETBE
is required. Also, cost of ETBE is higher than the same of MTBE.
Main Relation:
60 - 90oC
(CH3)2C = CH2 + C2H5OH t 5 (CH3)3COC2H5
9 atm
/-Butylene Ethanol ETBE
 508 Introduction to Process Engineering and Design

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Process Engineering Channel
@ProcessEng

= 2 o ■0.
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 Process Design of Distillation Columns 509 [

Side reactions:
(1) (CH3)2C = CH2 + (CH3)2C=CH2 ((CH3)2C = CH2)2
/-Butylene Diisobutylene
(2) (CH3)2C = CH2 + H20 < => (CH3)3COH
/-Butylene Water /-Butyl alcohol

8.7.5.1 Conventional Process

Isobutylene rich stream is water washed in wet scrubber to remove trace con-
taminants that can deactivate the catalyst. Then this stream is mixed with recti-
fied spirit and mixture is sent to isothermal, shell and tube type plug flow reactor.
Ethanol is used as excess reaclant. Second reactor is operated adiabatically. Product
from second reactor is sent to distillation column. In first distillation column,
mixture of ethanol, water and isobutylene is separated from ETBE. Ethanol can-
not be separated from the distillate of first column by common distillation be-
cause ethanol forms azeotrope with isobutylene as well as with water.
Further addition of water as solvent separates ethanol and water mixture from
isobutylene in liquid-liquid extractor. Isobutylene rich stream is coming out from
the top of extractor as light product or as raffinate. Ethanol - water stream or
extract stream leaves from the bottom of the extractor. From the extract phase,
azeotrope (95.6% ethanol and 4.4% water by mass) is separated by distillation
and it is recycled back to the reactor.
Bottom product of first distillation column is ETBE-ethanol mixture from
which ethanol is separated from ETBE by distillation.

8.7.5.2 Reactive Distillation Process28

In reactive (catalytic) distillation technology only equilibrium conversion is in-
creased in reactive distillation unit. Up to almost 80% conversion of isobutylene
is achieved in a (conventional) separate isothermal shell and tube heat exchanger
type plug flow reactor. Hence, feed to reactive distillation column is rich in ETBE
but still contains ethanol and isobutylene. Instead of rectified spirit, absolute al-
cohol is used as raw material with isobutylene.
Overhead product from reactive distillation column is non-reactive hydrocar-
bons (n-butane, n-butylene, etc.), isobutylene and ethanol, respectively.
Reactive Distillation column has total ten packing sections. First and second
Process Engineering Channel

packing sections use simple structured packing, act as rectification or enriching

section. Third, fourth and fifth packing sections use ordered packing and act as
reactive distillation zones. Sixth to tenth packing sections used simple structural
packing which act as stripping section.
Typical data of this process are as follows.
(a) Feed composition: 29.1% ETBE, 9.1% ethanol,
@ProcessEng

73% isobutylene, 54.5% n-butylene (by mole)

(Feed to reactive distillation unit)
(b) Isobutylene conversion: 97.4%
(c) Operating pressure = 900 kPa a
(d) Reflux ratio = 5.0
(e) Bottom composition = 96.5% ETBE, 2.8% ethanol
0.7% butylene, 0.04% diisobutylene (by mole)
 510 Introduction to Process Engineering and Design

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 Process Design of Distillation Columns

(f) Distillate composition = 96.5% n-butylene, 1.7% isobutylene,

0.7% ethanol (by mole)

8.7.7 Effect of Various Parameters on Reactive

Distillation of ETBE

(i) Effect of Feed Composition: Increase in isobutylene percentage in feed

(isobutylene rich stream) results in
(a) Decrease in energy cost per kg of ETBE produced. As lesser energy is
"wasted" in heating and cooling of inert compounds.
(b) Decrease in size and fixed cost of reactive distillation unit and associated
equipments for the same production rate of ETBE.
(c) Increase in the reactant concentrations in reaction zone, increases reaction
rate as well as equilibrium conversion.

Pt
f(Xe) = Koc (8.108)
n
\ t;
In this reaction Aii = change in moles during reaction = 2 - 1 = 1. Hence
decrease in total number of moles of reaction system increases the value of
equilibrium conversion Xe.
(d) Increase the temperature of reaction zone due to decrease in stabilizing
effect of inert components. Reaction is exothermic.
(ii) Effects of Excess Ethanol: Excess of ethanol is required to suppress rate of
side reactions and to increase yield of ETBE. But, increase in excess of ethanol
decreases the purity of ETBE as a bottom product of reactive distillation. It has
been found that 4% to 7% excess ethanol is sufficient to produce high yield of
ETBE without affecting the purity of ETBE as a bottom product from the reac-
tive distillation unit.
(iii) Effect of Column Pressure: In conventional distillation, operating pressure
is decided based on use of cooling water or cheaper cooling medium in overhead
condenser. Sometimes, to avoid the thermal cracking of product or to alter the
vapour-liquid equilibrium or to facilitate the use of cheaper heating medium, etc.
conventional distillation is carried out in vacuum.
However, in reactive distillation, choice of operating pressure is more compli-
cated. In reactive distillation pressure affects equilibrium conversion of reaction.
Process Engineering Channel

In ETBE, synthesis moles are decreasing during reaction, hence higher pres-
sure is favourable as it increases equilibrium conversion. But, this is not always
true, as increase in pressure increases temperature of reaction zone of reactive
distillation unit. Since ETBE synthesis is exothermic reaction, increase in tem-
perature decreases equilibrium conversion. It is found that best conversion is
achieved at 400 to 500 kPa a. But considering distillation aspect, operating pres-
sure is kept 700 to 900 kPa a.
@ProcessEng

(iv) Effect of Reactive Distillation Stages: Increase in length of reactor zone or

increase in number of stages of reactive distillation zone improves the conver-
sion, but at the same time decomposition of product starts in the lower stages, if
the number of stages increased above the optimum number of stages.
(v) Effect of Separation Stages: Ideally the rectification or enriching section of
reactive distillation column for ETBE synthesis should (a) remove light inerts
 Introduction to Process Engineering and Design

from reaction zone, (b) prevent loss of ether or alcohol in distillate and (c) recy-
cle unreacted reactants to the reaction zone. In actual practice this is almost im-
possible to achieve as favourable conditions for the reaction cannot be changed.
However, the loss of ETBE in distillate can be minimized without rejecting
isobutylene from the column. More enriching stages are required to prevent loss
of ethanol with distillate.
Ideally stripping section should:
(a) Remove ETBE from the reaction zone to maintain favourable reaction con-
ditions.
(b) Purify the ether (ETBE) product.
(c) Prevent loss of reactive isobutylene with ether (ETBE) product.
(d) Minimize ethanol loss with the ether product.
These functions are easily achievable at temperature and pressure of reaction
conditions.
(vi) Effect of Reflux Ratio:
Effect of increasing reflux ratio are
(a) The concentration of reactants in the distillate is reduced.
(b) The reaction zone temperature reduces which is favourable for exothermic
reaction to increase equilibrium conversion.
(c) The concentration of ether in the reaction zone reduces. It reduces catalytic
cracking of ether (ETBE).
All these three effects increase the conversion. However, higher reflux ratio
increases tower diameter, condenser and reboiler sizes and energy requirements.
(vii) Effects of Feed Point:
In ETBE synthesis, optimum feed point for reactive distillation column is just
below the reactive distillation zone. In reaction zone, ETBE can decompose or it
can react by cracking reaction in presence of catalyst. So to avoid the decompo-
sition of ETBE in the feed (i.e. ETBE rich stream), it is fed just at the bottom of
reaction zone. Feeding too far below the reaction zone reduces the stripping po-
tential and increases energy requirement for the same height of stripping section.
(viii) Effects of Reboiler Duty:
At some optimum value of reboiler duty, higher conversion (more than 95%) and
higher purity (~ 90%) is achieved. If reboiler duty is too high or too low, conver-
sion and product purity both are reduced.
Process Engineering Channel

Manufacture of ETBE was discussed as a case study of reactive distillation so

that a process engineer can learn to analyse a system before actual process design
is taken up.

8.7.8 Manufacture of Ethyl Propionate

Ethyl propionate can be synthesized29 by esterification of ethyl alcohol

with propionic acid in a reaction distillation unit using cation exchange resin as
@ProcessEng

catalyst.

8.8 AZEOTROPES AND SEPARATION THEREOF

In the previous sections, distillation of liquid mixtures was dealt which are
amecable to ordinary fractional distillation. In these cases, VLE plot or an equi-
librium curve of a binary is on one (upper) side of the diagonal line. However,
 Process Design of Distillation Columns

when the equilibrium curve crosses the diagonal line, an azeotrope occurs. Thus
at a given pressure, a mixture of specific composition boils at a constant tempera-
ture which produces vapour of the same composition. When this happens, the
mixture cannot be separated and it is known as azeotropic mixture. When the
vapour of the azeotropic mixture are condensed, liquid mixture so obtained de-
cides the type of azeotrope. If the condensed liquid phase is homogeneous, it is
called a homogeneous azeotrope. Ethanol-water forms homogenous azeotrope at
101.325 kPa and 78.10C having 95.6% ethanol (by mass). Figures 8.42 (a) and
(b) and Figs 8.43 (a) and (b) refer to homogeneous azeotropes.

118
117.5
\ Pressure = 101.325 kP a
116

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/N /
Liquid composi
106
Azeotropic point ^
105.50C
104
0.2 0.4 0.6 0.8 1.0
(a) Mole fraction toluene in liquid
1.0
—- Pressure = 101.325 kPa^/
3
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Process Engineering Channel

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@ProcessEng

0 0.2 0.4 0.6 0.8 1.0

(b) Mole fraction toluene in liquid

Fig. 8.42 (a) t-x-y Diagram for Toluene-n-Butanol System, (b) Homogeneous Minimum Boiling
Azeotrope of Toluene-n-Butanol System30
(Reproduced with the permission of Chemical Engineering by Access Intelligence, USA)
 Introduction to Process Engineering and Design

66
Azeotropic point
64.50C ^

64
Vapour —>:
composition /
' Liquid composition \\
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Pressure = 101.325 kPa

54
0.2 0.4 0.6 0.8 1.0
Mole fraction chloroform in liquid

1.0
Pressure = 101.3^>5 kPa

§ 0.8
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Process Engineering Channel

o
2 0.2

0
0 0.2 0.4 0.6 0.8 1.0
Mole fraction chloroform in liquid
@ProcessEng

Fig. 8.43 (a) t-x-y Diagram for Chloroform-Acetone System, (b) Homogeneous Maximum Boiling
Azeotrope of Chloroform-Acetone System30
(Reproduced with the permission of Chemical Engineering by Access Intelligence, USA)

A heterogeneous azeotrope is one for which the overall liquid mixture forms
two liquid phases. Mixture of n-butanol-water forms an azeotrope at 101.325
 Process Design of Distillation Columns

kPa and 92.20C having 57.5% (by mass) or 24.8% (by mole) n-butanol in the
overall liquid mixture. It separates in two layers. At 40oC, top layer contains
78.51% n-butanol while the bottom layer contains 6.60% n-butanol (by mass).
Refluxing a specific layer provides a method to separate the components of the
mixture. Figures 8.44 (a) and (b) refer to heterogeneous azeotrope.

120
117.50C
^
Pressure = 101.325 kPa
115

110
U
o
3
2 105
D. Vapour compositioi —V
S
£
100

r,
95
/A Liquid
1
composition
"T. Azeotropic p oint
92.20C
90
0.2 0.4 0.6 0.8 1.0
Mole fraction n-Butanol in liquid
(a)
1.0
Pressu re = 101.3 25 kPa
//
§ 0.8
&
>
/ /
o
c 0.6
2
3
CO
c /
c
Process Engineering Channel

/
-2 0.4
tfcl x
o 1 /
S 0.2

0.2 0.4 0.6 0.8 1.0

@ProcessEng

Mole fraction /;-Butanol in liquid

(b)
Fig. 8.44 (a) t-x-y Diagram for n-Butanol-Water System, (b) Heterogeneous Minimum Boiling
Azeotrope of n-Butanol-Water System30
(Reproduced with the permission of Chemical Engineering by Access Intelligence. USA)
 Introduction to Process Engineering and Design

The temperature at which an azeotrope is distilled is important. A minimum

boiling azeotrope is one for which the boiling temperature is less than that of
pure components. Figures 8.42(a) and (b) and Figures 8.44 (a) and (b) are t-x-y
and y-x diagrams of minimum boiling azeotropes. For example, at 101.325 kPa,
n-butanol and water boil at 117.70C and 100oC, respectively but their azeotrope
boils at 92.20C. In case of maximum boiling azeotrope, the boiling point of the
azeotrope is higher than that of the pure component. Chloroform and acetone
boil at 61.20C and 56.40C, respectively at 101.325 kPa. The mixture of these two
compounds forms a maximum boiling azeotrope at 64.50C, containing 65.5%
(by mole) chloroform. Figures 8.43(a) and (b) are t-x-y and y-x diagrams of the
system, comprising chloroform and acetone. Maximum boiling azeotropes are
usually homogeneous. About 90% of the known azeotropes are of the minimum
variety.
Azeotropic data are well tabulated in literature. Perry's Chemical Engineers'
Handbook tabulate data for binary and ternary azeotropes of common interest.
Extensive 3-volume compilation by J. Gmehling (Ref. 8) cover pratically all
known azeotropes.
Property of some organic compounds to form azeotropes with water is advan-
tageously used in many chemical reactions. Manufacture of amino resins involve
etherification/esterification reactions. Water is a product of reaction. One of the
reactants is r2-butanol which forms a heterogenous azeotrope with water. While a
batch of reaction is in progress, water is removed from the mass as an azeotrope.
The vapours of azeotropic composition is condensed which separates into two
liquid layers. Top n-butanol rich layer is recycled to the reactor and bottom aque-
ous layer is removed. This way one of the products of reaction is removed from
the reaction mass, thereby reaction proceeds in forward direction.
In manufacture of alkyd resins also, water is a product of reaction. Toluene or
xylene is added to the reaction mass and water is removed from the mass in form
of a heterogeneous azeotrope. On condensation, two layers separate. Water is
sparingly soluble in the hydrocarbon. Top hydrocarbon layer is recycled to the
reactor.
In all esterification reactions, water is a byproduct. It is a common practice to
remove water in the form of an azeotrope from top in a specially designed distil-
Process Engineering Channel

lation column.
Removal of water in the form of an azeotrope has also expedited other opera-
tions, such as nitration of benzene and toluene. In this case, water formed in the
nitration of the hydrocarbon is removed continuously, utilizing hydrocarbon it-
self as an entrainer. Contrary to semi-containuous operation, mixed acid, consist-
ing of nitric acid and sulphuric acid, is used for nitration in a batch reactor. This
@ProcessEng

batch process suffers from a drawback of disposal of spent acid or recovery of

acids from the spent acid is a problem. Bottom still acts as a reaction vessel in
which nitric acid and excess hydrocarbon are intially charged. Nitrated hydrocar-
bon has higher boiling point and thus remain in the still. Azeotrope of hydrocar-
bon and water goes to the bottom of the dehydrating column. Optimum tempera-
tures and concentrations can readily be maintained in the system with simple
 Process Design of Distillation Columns 517

controls. Parameters, normally required to be controlled are feed rates of nitric

acid and hydrocarbon, rate of supply of heal to respective heating units and rate
of withdrawl of water at the top of the dehydrating column. Product is thus formed
in single pass with almost 100% yield on both; nitric acid and hydrocarbon.
Similar azeotropic process is continuous production of acetamide. Continu-
ous streams of ammonia and acetic acid are fed to a dehydrating column. Ammo-
nium acetate, so formed is continously dehydrated in azeotropic distillation sys-
tem to give water and acetamide. Water, formed in both the reactions, goes over-
head with the help of an entrainer. Acetamide with excess acetic acid flow out
from the bottom of the column. This mixture is sent to second distillation column
from which pure acetamide is withdrawn from the bottom. Acetic acid vapour
from the column are recycled back to reaction cum azeotropic distillation
column.
In general, following are the methods, used for separating azeotropic mixtures.
(a) As mentioned earlier, azeotrope is dependent on operating pressure in most
cases. If pressure is altered, it may be possible to avoid an azeotrope thereby
fractional distillation can be carried out. For example, if distillation of etha-
nol-water is carried out below 70 torr, no azeotrope exists. However, this
method is limited by many factors in actual practice. However, a few
azeolropes do not change composition with pressure. For example, n-hexane
forms an azeotrope with ethanol30, containing 21.0% ethanol (by mass). It
boils at 58.70C at 101.325 kPa. However, the composition of this azeotropic
mixture is unchanged over the pressure range of 20 torr to 10 000 torn
(b) A popular method is to add specially chosen chemical to shift the azeotropic
point to a more favourable position. When this chemical (also known as
entrainer) appears in appreciable amounts at the top of the column, the
operation is called azeotropic distillation. When the additional component
(called solvent) appears mostly at the bottom of the column, the operation
is called extractive distillation.
(c) In distillation using ionic salt, the salt dissociates in the liquid mixture and
alters the relative volatilities sufficiently that the separation becomes possi-
ble like fractional distillation.
(d) Pressure-swing distillation is yet another method where a series of columns,
Process Engineering Channel

operating at different pressures, are used to separate binary azeotropes which

change appreciably in composition over a moderate pressure range or where
a separating agent which forms a pressure-sensitive azeotrope is added.
(e) Use other techniques like pervaporation or adsorption for separating a com-
ponent (such as water) from the azeotrope. These techniques are discussed
in Sec. 8.8.3.
@ProcessEng

(f) Reactive distillation can be considered where the separating agent reacts
preferentially and reversibly with one of the azeotropic constituents. The
reaction product is then distilled from the non-reacting components. Dilute
alcohol solutions or dilute aqueous acetic acid solution can be treated by
this method to form esters in reactive distillation units.
 Introduction to Process Engineering and Design

8.8.1 Azeotropic Distillation

Heterogeneous azeotropic distillation is a widely practiced process for dehydra-

tion of number of compounds such as acetic acid, chloroform, ethanol, acetonitrile,
etc. The technique involves addition of a third component in a homogeneous
azeotrope, called an entrainer to form a minimum boiling ternary azeotrope, car-
rying water overhead and leaves near dry (pure) product in the bottom. The over-
head vapours are condensed to two liquid phases; entrainer rich phase is refluxed
while the aqueous phase is decanted.
Dehydration of ethanol-water mixture is carried out with the help of benzene
as an entrainer. Ethanol and water forms azeotrope having 95.6% ethanol (by
mass) at 78.150C and 101.325 kPa. When benzene is added to the azeotrope
(about 0.427 kg/kg azeotrope) it comes as ternary azeotrope at the top containing
74.1% benzene and 18.5% ethanol (by mass). Bottom product from the column
is pure dry ethanol. Top azeotrope at 650C is condensed which forms two layers.
Top layer contains 90.9% benzene by mass (and practically no water). It is refluxed
to the column. Bottom aqueous layer contains 53% ethanol and 11% benzene (by
mass). Since this layer contains appreciable content of benzene, it can be dis-
tilled in another column to recover it in the form of ternary azeotrope. Water is
removed from the bottom of the third column. Thus three columns are normally
required for this distillation.
Process design of an azeotropic distillation system for separation of ethanol-
water using trichloroethylene is given by Coates30 and using benzene is given by
Norman31.
Another entrainer for ehtanol dehydration is n-pentane which is eco-friendly.
The tower is operated at near 3.45 bar a. Total condenser operates at 3 bar a and
a ternary azeotrope, containing 82.64% n-pentane and 12.33% ethanol (by mole)
is formed. Condensate separates in two layers, top layer contains 87.9% n-pen-
tane and 11.6% ethanol (by mole) and is refluxed to the column. Bottom aqueous
layer contains 23.8% ethanol (by mole) and practically no n-pentane. This layer
is distilled in second column to recover ethanol as azeotrope with water as top
product. In this case only two columns are required.
Another example of separation of homogeneous azeotrope is that of iso-pro-
panol-water. It form azeotrope at 80.4oC and 101.325 kPa. For their separation,
Process Engineering Channel

cyclohexane or benzene is used as entrainer. Cho and Jeon32 have given process
design of heterogeneous azeotropic distillation system for dehydration of iso-
propyl alcohol using benzene as the entrainer.
When the binary azeotrope is hetergeneous, separation of the components are
possible without addition of an entrainer. Design of n-butanol-water distillation
system is given by McKetta and Cunningham33 in detail.
@ProcessEng

8.8.2 Extractive Distillation

Extractive distillation can be defined as distillation in the presence of a miscible,

high boiling relatively non-volatile component (called the solvent) that forms no
azeotropes with other components of the mixture. Solvent is continuously added
near the top of the column so that an appreciable amount is present in the liquid
 Process Design of Distillation Columns 519 |

phase throughout the column. The component having the greater volatility (not
necessarily the lowest boiling point component) is taken overhead as a relatively
pure distillate. The other component leaves with the solvent via the column
bottoms. The solvent is then separated from the bottoms in second distillation
column. Selection of an extractive distillation solvent is the most important step
in developing a successful extractive distillation sequence. Important selection
criteria are given below.
(i) It should enhance the relative volatility of the key component significantly.
(ii) Required solvent quantity to be added to the azeotropic mixture should not
be excessive.
(iii) It should be soluble in the feed components.
(iv) It should be easily separable from the bottom product.
(v) It should be relatively inexpensive and easily available.
(vi) It should be stable at the operating conditions of both the columns.
(vii) It should be non-reactive with the feed components.
(viii) It should have low latent heat of vaporization.
(ix) It should be non-corrosive and non-toxic.
(x) It should not form immiscible liquid mixtures at any point in the column.
Perrys' Chemical Engineers' Handbook serves as a good reference for the
solvent selection.
Cyclohexane is manufactured from benzene. The mixture from the reactor
comes out with the desired product (cyclohexane) and also a significant amount
of unreacted benzene which is to be recycled back to the reactor for economic
reasons. Product mixture contains nearly 45% cyclohexane and balance benzene
(by mole). It is desired to operate the distillation column at 150 kPa a as dictated
by the proces flow sheet. At this pressure, cyclohexane and benzene boil at 94.30C
and 93.50C, respectively. Binary homogeneous azeotrope at this pressure is formed
at 910C, containing 45.5% cyclohexane (by mole) which is nearly the same com-
position of reactor exit product mix. In this case propylene glycol is selected as a
solvent as benzene is highly soluble in the solvent. Further the solvent has high
boiling point (200.4oC) at 150 kPa and no new azeotropes are formed. Distillate
from the column is 99.3% pure cyclohexane. Bottoms from the first column is
fed to second column from which distillate is 85% pure benzene which is recy-
Process Engineering Channel

cled back to the reactor. Bottoms from the second column is nearly pure solvent
which is recycled to the first column.
Apart from organic solvents, inorganic salts such as potassium and sodium
acetates, calcium chloride, calcium nitrate, etc. can also be used to break the
azeotropes.
Another well known example of extractive distillation is dehydration of nitric
acid-water azeotrope (containing 64.1% HNO3 by mass at 101.325 kPa and
@ProcessEng

1220C). In this case sulphuric acid is used as solvent.

Apart from above examples, extractive distillation finds many applications in
the petroleum refinery. Pyrolysis gasoline byproduct from naphtha steam crack-
ing contains a wealth of aromatics. Separation of aromatics, such as xylenes, is
carried out by extractive distillation. Similarly, extractive distillation can be used
 Introduction to Process Engineering and Design

to selectively extract the sulphur species from cracked gasoline to very low levels
without loosing its octane value.

8.8.3 Pressure Swing Distillation

Although known from good olden days, only now pressure swing distillation
technique is gaining popularity for separation of a binary azeotrope over hetero-
geneous azeotropic distillation and extractive distillation. The chief reason for
not finding many industrial applications till date was the lack of experimental
VLB data for binary systems at different pressures. Two main advantages of pres-
sure swing distillation are; energy saving by heat integration of the system and no
need to add an entrainer or a solvent for the separation.
The technique is based on the principle that the composition of almost all
azeotropes varies with the operating pressure. In industrially important water-
solvent mixtures, the water content of the azeotrope increases with increasing
pressure. This variation provides a technique for separation of the components.
A shift in composition of azeotropic mixture with respect to pressure can be well
understood by studying Figures 8.45 (a) and (b).
Acelonitrile—ACN (also called methyl cyanide; formula: C2H3N) forms a
minimum boiling azeotrope with water at 1 atm and 770C containing 83.5% by
mass or 69.0% by mole ACN. This azeotrope composition shifts to 60.0% by
mole ACN at 3.02 bar a which boils at 112.50C. Using these data a two-column
system can be designed to operate at two different pressures to separate ACN and
water from the mixture. Feed with lower concentration than 69.0 mole % ACN
can be fed to the first column operating at 1 atm. Distillate from the column with
near azeotropic composition is the feed to the second column operating at 3.02
bar a. Bottom products from the first and second column are water and ACN,
respectively. Distillate from the second column is recycled to the first column
along with the fresh feed.
An important point to note is that in heterogeneous azeotropic distillation,
bottom product from the first column is the solvent (low boiling component)
while in pressure swing distillation, bottom product is water (high boiling
component).
In pressure swing distillation since both the columns operate at different pres-
Process Engineering Channel

sures, their heat exchangers can be readily thermally integrated. This will result
in substantial savings in energy for distillation. However, such an integration
results in complexity of the system which requires adequate process control
instrumentation. Also hazards of handling flammable (and toxic) solvents at high
pressure must be given due considerations while designing such a system.
Both batch and continuous systems are developed. Jen-Uwe Repke et al35,36
have developed mathematical models and process control systems for ACN-
@ProcessEng

water mixture.
Knapp and Doherty37 have listed more than 35 pressure sensitive binaries which
can be separated by pressure swing distillation technique.
Ethanol-water is also a pressure sensitive azeotrope but its separation by pres-
sure swing distillation method is considered an uneconomical proposition. For
 Process Design of Distillation Columns

140 -
133.80C -
P2 = 3.02 bar Azeotropic point
:
130 {x= y = 0.6)
at 112.50C 121.50C
120 -
\\
110 -
u
o :
px = 101.325 kPa
100 J Azeotropic point
{x=y = 0.69)
: at 770C
90

] 81.90C
80 -

70 1 I I I T
0 0.2 0.4 0.6 0.8 1.0
x,y
(a)
1.0
/
Azeotropic poiiIt
(x=y = 0.69) //
0.8 - ai^ -7-70/-'
// ^
\
P\ = 101 325 kPa
0.6 "

I Azeotropic point
"Pi = 3.02 bar V
(x=y = 0.6)
0.4 -
at 112.50C
1 1

0.2

/
Process Engineering Channel

0 t 1 r
0 0.2 0.4 0.6 0.8 1.0
x
(b)
Fig. 8.45 (a) t-x-y Diagrams for Acetonitrile-Water System, (b) Homogeneous Minimum
Boiling Azeotropes Acetonitrile-Water System34
(Reproduced with the Permission of Dr. Repke)
@ProcessEng

separation of this azeotrope, Knapp and Doherty37 have suggested to add small
amount of acetone in the dilute alcohol stream from a fermenlor. The entrainer
does not form a ternary azeotrope at atmospheric pressure but forms a ternary
azeotrope at high pressure (say at 10 aim). On this basis a scheme is presented to
operate first column at 1 atm and second column at 10 atm. Resulting pressure
sequence yields dry elhanol from the bottom of the second (HP) column. Also
 522 Introduction to Process Engineering and Design

thermal integration of both the columns result in nearly 53% energy saving over
the conventional heterogeneous azeotropic distillation sequence.
Exercise 8.12 is yet another example of separation of tetrahydrofuran (THE)
from aqueous THE solution using pressure swing distillation technique.

Example 8.16
Isopropyl alcohol (IPA) forms a minimum boiling azeotrope with water at 80.4oC and
101.325 kPa, having a composition of 31.47 mole % water. Vapour pressure of IPA can
be calculated using Antoine equation13.

1359.50
log pv = 6.8651 -
(T-75.65)
where. pv = Vapour pressure. kPa
T = Saturation temperature, K
(a) A feed consisting of 50 mass % IPA under saturated liquid conditions is to be
distilled to give 67.5 mole % IPA as distillate (near azeotrope) and 0.1 mole %
(0.0033 mass %) IPA in the bottoms. Using McCabe-Thiele technique and for
R = 3, find the number of theoretical stages, required for the separation at 1 atmos-
phere and locate the feed introduction stage.
(b) Make tray-to-tray calculations for the desired separation using van Laar constants.
Solution:
Azeotrope contains 0.3147 mole fraction (0.121 mass fraction) water. To find the non-
ideal behaviour of the IPA-water system, use of van Laar equation can be made. Assum-
ing vapour fugacity (i.e. vapour escaping tendency) to be unity at low pressure,
P-yi = XtYiPvi (0
where. p = Total pressure of the system = 1 atm = 760 torr
y(- = Mole fraction of /th component in vapour
a: = Mole fraction of /th component in liquid
7 = Activity coefficient of /th component
P^ = Vapour pressure of the /th component at the boiling point, torr
If *1 and Xj are mole fractions of the two components in a binary liquid mixture.

x
2
In y, =A (8.109)
Xl + X2
Process Engineering Channel

In yj = /^ (8.110)
— |X2 + A",

Equations (8.109) and (8.110) are called van Laar equations and A and B are called
@ProcessEng

van Laar constants. Let 1 refer to IPA, the more volatile component and 2 refer to water.
Boiling point of the azeotrope, r = 80.4oC or T = 353.55 K.

1359.50
log Pvi =6.8651 - = 1. 973 05
(353.55 - 75.65)

pvi = 93.984 kPa (vapour pressure of IPA at 80.4oC) = 704.94 torr

 Process Design of Distillation Columns

From steam tables, at t =80.4oC, pv2 = 48.14 kPa = 361.08 torr

At the azeotropie point,
y, =760/704.94= 1.0781
72 =760/361.08 = 2.1048

0.3147
In (1.0781)= A
— 10.6853 + 0.3147
B

0.6853
In (2.1048) = B
/?
0.3147 + 0.6853
A

Solving the equations by Mathead,

A =2.311 87 and B = 1.107 77

These constants are themselves functions of the liquid compositions but their varia-
tions can be ignored for all practical purposes (for low heats of mixing) at a given total
pressure and varying temperature conditions. Using these constants, van Laar equations
can be used to develop the vapour-liquid equilibrium curve.
Consider x, = 0.6 (of 1PA) anda^ = 0.4 (of water) and calculate activity coefficients.
In 7, =0.135 51 or 7, = 1.145 12
In 72 = 0.636 31 or 7, = 1.889 49
Assume boiling point of the mixture to be 8 l0C (or 354.15 K),
pvl = 96.292 kPa = 722.25 torr
pv2 = 49.311 kPa = 369.86 torr
p = ixrrr pvi
= (0.6 x 722.25 x 1.145 12) + (0.4 x 369.86 x 1.889 49)
= 496.24 + 279.54 = 775.78 torr
^760 torr
Since total pressure does not equal to 760 torr, assume new temperature equal to
80.5oC (353.65 K).
Process Engineering Channel

pvl = 94.365 kPa = 707.8 torr

pv2 = 48.336 kPa = 362.55 torr
p = (0.6 x 707.8 x 1.145 12) + (0.4 x 362.55 x 1.889 49)
= 486.31 +274.0 = 760.31
= 760 torr
Mole fraction of IPA in vapour (corresponding to JCj), y, =xl ■ y ■ pv]
@ProcessEng

= 0.6x707.8 x 1.145 12/760

= 0.64
In this manner, x-y data can be generated for the entire range which is tabulated in
Table 8.45.
 Introduction to Process Engineering and Design

Table 8.45 Vapour-Liquid Equilibrium of IPA-Water at I atm

Mole fraction of IPA Boiling point (/), 0C

in Liquid in Vapour
X y
0 0 100.0
0.02 0.2495 92.65
0.05 0.3993 87.4
0.075 0.4561 85.15
0.1 0.489 83.85
0.2 0.5371 82.0
0.3 0.5545 81.5
0.4 0.573 81.3
0.5 0.6 80.8
0.6 0.64 80.5
0.6853 0.6853 80.4 (azeotrope)
0.8 0.7682 80.6
0.9 0.87 81.15
0.95 0.93 81.65
1.0 1.0 82.5

Figure 8.46 is the plot of the vapour-liquid equilibrium of IPA-water system.

Feed (zF) is marked at x, = 0.2306 (equivalent to 0.5 mass fraction) of IPA. Desired
purities of distillate and bottoms are marked at xD = 0.675 and = 0.001. ^-line is
vertical as the feed is saturated liquid.

—^— = 0.3537
CKm+l)
Rm = 0.9084
In case of azeotropic distillation, other methods are available in literature37 for calcu-
lation of minimum reflux ratio which are more reliable. Also actual reflux ratio is kept
much higher than the minimum.
For R=3

Xd
= =0.1688
Process Engineering Channel

(tf+D (3 + 1)
For R = 3, from. Fig. 8.46, total 10 theoretical stages are required for the separation
and feed will be introduced at 3rd stage from bottom.
(b) Tray-to tray Calculations:
Azeotropic distillation column design of IPA-water system can be carried out by nu-
merical method; i.e. tray-to-tray calculations. Average latent heats of vaporization of
@ProcessEng

IPA and water are 40 093 and 41 081 kJ/kmol, respectively. Activity coefficients for
each tray liquid mixture will be calculated using same van Laar constants, used for
developing Table 8.45.
Basis: 100 kmol/h of feed consisting of 0.2306 mole fraction IPA.
With distillate, containing 0.675 mole fraction IPA and bottoms, containing 0.001 mole
fraction IPA, material balance yields
 Process Design of Distillation Columns 525

1.0
/
/
0.7C Detail 'A' 7
0.9
/
7
7 -
0.8 Azeotrc pic poin
0.65 V-* *
X
7
// 7- v-7 "A
0.7
A ( (
0-60 o.65 0.70
0.6
1 7^
1/i-T— INF 7
A X/
0.5
/
/ / /
7
/
0.4
—► 1/

^-1 /
0.3
/7 /
/ /
/ / A nnin tr/l rr
/ / No. of trays in
/ / Enriching section =8
/ No. of trays in
0.1 / Stripping section 2
/ Total theoretical trays = 10
7 Pressure p = 1 aim
Z
o\ 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
xw = 0.001 zF = 0.2306 *D = 0.675

Fig. 8.46 Azeotropic Distillation of Aqueous Isopropyl Alcohol

D = 34.065 kmol/h and

IV= 65.935 kmol/h
Reflux R = 3D = 3 x 65.935 = 102.195 kmol/h

Liquid flow in column L =R+D

= 102.195 4-34.065
= 136.26 kmol/h
Vapour from the bottom most tray (No. 1),
Process Engineering Channel

V\ = L - W
= 136.26-65.935
= 70.325 kmol/h
For x, =0.001 (IPA) and X2 = 0.999 (water)
72 = 9.996 57 and 72 = 1.000 00
@ProcessEng

0
At tx = 99.46 C, yl = 0.0191 and y2 = 0.9809 (Refer Table 8.46)
Latent heat of vapour leaving Tray-1
A, = 0.0191 x 40 093 4- 0.9809 x 41 081
= 41 062.3 kJ/kmol
 526 Introduction to Process Engineering and Design

Table 8.46 Material Balance of Tray-1 (from Bottom)

Component Bottom Vapour, V, Liquid flow

product. W from Tray-2, L2
kmol/h mol. fr. kmol/h kmol/h mol. fr.
IPA 0.066 0.0191 1.343 1.409 0.0103
Water 65.869 0.9809 68.982 134.851 0.9897

Total 65.965 1.0000 70.325 136.260 1.0000

With x, =0.0103 and ;t2 = 0.9897

y, =9.157 97 and y2 = 1.000 50
0
At r2 = 95.54 C, yl = 0.1565 and y2 = 0.8435
A2 = 0.1565 x 40 093 + 0.8435 x 41 0810
= 40 926.5 kJ/kmol
Adjust vapour flow from tray-2 with molar latent heats of vapour from tray-1 and
tray-2.
k2 = 70.325 x 41 062.3/40 926.5
= 70.558 kmol/h

Table 8.47 Material Balance of Tray-2 (from Bottom)

Component ^2 ^2
kmol/h mol. fr. kmol/h kmol/h kmol/h mol. fr.
IPA 1.409 0.1565 11.042 1.343 11.108 0.0814
Water 134.851 0.8435 59.516 68.982 125.385 0.9186

Total 136.260 1.0000 70.558 70.325 136.493 1.0000

With *,=0.0814 and *2 = 0.9186

y, = 5.189 08 and y2 = 1.027 35
At t3 = 84.75°C, y, = 0.4661 and y2 = 0.5339
A3 = 40622.5 and V3 = 71.086 kmol/h
Process Engineering Channel

Table 8.48 Material Balance ofTray-3 (without Fresh Feed)

Component Li ^3 ^2 Z-4
kmol/h mol. fr. kmol/h kmol/h kmol/h mol. fr.
IPA 11.108 0.4661 33.133 11.042 33.199 0.2423
Water 125.385 0.5339 37.953 59.516 103.822 0.7577
@ProcessEng

Total 136.493 1.0000 71.086 70.558 137.021 1.0000

Composition of liquid mixture on tray-4 is 0.2423 mole fraction 1PA which is higher
than mole fraction 0.2306 of IPA in the fresh feed. Hence, feed is to be introduced on
3rd tray.
 Process Design of Distillation Columns 527 |

Table 8.49 Liquid Composition on Tray-4 after Addition of Fresh Feed on Tray-3

Component L4 F L
kmol/h kmol/h kmol/h mol. fr.
IPA 33.199 23.06 10.139 0.2739
Water 103.822 76.94 26.882 0.7261

Total 137.021 100.00 37.021 1.0000

Tray-to-tray calculations for the rectification section can be carried out in analogous
manner to the stripping section. These are summarised in Table 8.50.

Example 8.17
Refer Table 8.45 in Example 8.16. It can be seen that boiling point of 10 mole % IPA
mixture is 83.850C. This indicates that boiling point variation of only 1.350C takes place
from 0.1 mole fraction to the azeotropic point. Thus if the column is operated to separate
up to 0.1 mole fraction, the column operation is nearly isothermal. In the overhead con-
denser, cooling medium at 720C (max.) can be used while in the reboiler, heating me-
dium at 950C should be adequate.
For the above reason it is decided to operate the main column in the range of 0.1 mole
fraction to 0.675 mole fraction IPA. It will be provided its own reboiler as shown in
Fig. 8.47.
Liquid mixture, containing 0.1 mole fraction, is fed to another column in which open
steam will be used for stripping to achieve 0.1 mole % (0.0033 mass %) IPA in the
bottoms. Vapour from this column will be fed to the main column to supplement the
heat.
For the new arrangement, rework the number of theoretical stages, required for both
the columns for R = 3.
Solution:
Note: It can be noted that cooling medium at 720C is required in the overhead con-
denser while heating medium at 95 0C is required in the reboiler. This suggests water as
an auxiliary heat transfer medium in the heat pump (refer Sec. 8.8.1(f)). Saturation
pressure of water at 720C is 0.34 bar a and at 950C is 0.845 bar a. Compression ratio
across the turbo-compressor will be just 2.485.
In the second column, since live steam is to be injected, its temperature can be just
Process Engineering Channel

above 100oC. This permits use of flash steam at low pressure (may be at 105oC or 1.21
bar a) as live steam.
Use of live steam at low pressure and water as the auxiliary heat transfer medium in
the heat pump will make distillation quite energy efficient. Thermal energy require-
ment will be considerably reduced with this arrangement.
From Fig. 8.46 number of theoretical stages required for the separation up to 10 mole %.
@ProcessEng

IPA from 23.06% mole IPA (feed) N=S.

Second column is isothermal steam stripper. In stripping liquid, solution is contacted
with vapour or gas in a counter current manner to strip off the most volatile component
of liquid solution. Most volatile component of liquid solution is transferred to gas or
vapour. Stripping is a reverse of gas absorption. For stripping, low pressure and high
temperature are favourable.
 528 Introduction to Process Engineering and Design

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Process Engineering Channel

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@ProcessEng

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 Process Design of Distillation Columns 529

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Process Engineering Channel

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@ProcessEng

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 Introduction to Process Engineering and Design

CW

Distillate
67.5 mole % IPA

Main distillation
Water
column

Feed
23.07 mole %
I PA

<— Steam

10 mole % IPA

Stripper

Steam

Fig. 8.47 Azeotropic Distillation of Aqueous Isopropyl Alcohol (Conventional System)

Industrial strippers are of two types.

(i) In first type of stripper, hot gas/steam (can be called stripping agent) is introduced
at the bottom of stripper and the same is obtained from external source.
(ii) In second type, hot vapour is generated by partial vaporization of liquid solution in
reboiler at bottom. This type of stripper is like a bottom section (stripping section)
Process Engineering Channel

of distillation column. Feed solution is introduced from top and reboiler is provided
at the bottom. Reflux is not provided at the top. If the component to be separated
from feed is having very high relative volatility, then this type of stripper can be
selected.
In this example first type of stripper is selected. Stripping can be assumed as isother-
mal at 100oC.
Let, Cs = Molar flow rate of steam, kmol/h
@ProcessEng

Ls = Molar flow rate of water of feed, kmol/h

y moles of IPA in vapour phase

V=
1— y moles of steam in vapour phase
 Process Design of Distillation Columns

x moles of IPA in liquid phase

A— —
I -x moles of water in liquid phase
Equilibrium data can be approximated from Table 8.45.
X y X y
0 0 0 0
0.02 0.2495 0.0204 0.3324
0.05 0.3993 0.0526 0.6647
0.075 0.4561 0.081 0.8385
0.1 0.489 0.1111 0.957
Equilibrium curve is plotted in Fig. 8.48.
Minimum amount of steam required for desired separation can be obtained by follow-
ing equation.
Gsni(ylm-y2) = Ls(xl-x2) (8.111)
where y, and X, represent the molar ratios at top of the stripper and y2, X2 represent the
molar ratios at the bottom of stripper.
Here equilibrium curve is concave upward, hence y|m is equilibrium value of y corre-
sponding to the value of XF.

xF = 0.1, XF= —=0.1111

i-xF

y|m = 0.957 (From Fig. 8.48)

Q QQ1
y2 = 0, X, = XF = 0.1111, X2 = = 0.001
1 - 0.001

Ls{Xp-X2)
Gsm =

/
Gs \ 0.1111-0.001
or = 0.115
Ls I 0.957 - 0
'm

Let actual amount of steam, G = 1.5 G sin

Process Engineering Channel

G Xp - X2
— = 1.5 x0.115 = 0.1725 =
L, yi-y2

0.1111-0.001
0.1725 = -
y,-o
y, = 0.6383
@ProcessEng

Draw the operating line starting from (X2, y2) to (X,, y,). Staircase construction between
equilibrium curve and operating line, starting from (X,, T,) to (X2, y2) gives number of
theoretical stages required for the desired separation. From Fig. 8.48, no. of theoretical
stages required in the steam stripper; N = 6.
 Introduction to Process Engineering and Design

Equilibrium curve

IV
1,1

1.0
Vm >

0.9

0.8

0.7

0.6

0.5
or

0.4 Operating
line

0.3
o.i

0.2
Operating line
Process Engineering Channel

A.
Detail 'A' 0XX2==0001 0.1

0. 0.2 0.3
n
^2 = 0.001 ^f=O.IIII
X
@ProcessEng

Fig. 8.48 Stripping of Dilute /PA with Live Steam

Example 8.18
Ethanol forms a minimum boiling azeotrope at 78.150C and 101.325 kPa, with water
having composition of 10.57 mole % water. Vapour pressure of ethanol can be calcu-
lated using Antoine equation13.
 Process Design of Distillation Columns

Contaminated water recycle i

cw

Option II
Absolute elhanol pcrvaporation unit

Option I
CW conventional
distillation

Azcotropc recycle
CW
r~-

i 4 mole% water
;111 ( ) Hxd
Aqueous CaCI
Solution (25 mass%)
Extractive Steam
distillation
Reject column Absolute
water elhanol
Feed
28.13 mole%
elhanol

Steam Steam Steam

CW

J—Q Steam

Absolute
S elhanol
Contaminated water recycle Option III
molecular sieve
drying unit

Fig. 8.49 Extractive Distillation of Aqueous Ethanol with Aqueous Calcium Chloride Solution
(25 mass %)

1592.90
log pv = 7.2371 -
(T - 46.95)
Process Engineering Channel

where, pv = Vapour pressure, kPa

T = Saturation temperature, K
Extractive distillation technique is known for separation of an azeotrope using a sol-
vent. In a newly developed process, aqueous inorganic salt solution is used as a solvent
to break the azeotrope. Lowering of vapour pressure is experienced when an inorganic
salt is dissolved in water. Vapour pressures of aqueous calcium chloride solutions are
given in Table 8.51.
@ProcessEng

It is proposed to use aqueous 25% CaCL solution (by mass) as a solvent for dehydra-
tion of aqueous ethanol. Proposed flow diagram is shown in Fig. 8.49.
Plot x-y diagrams of ethanol-water system at 101.325 kPa, with and without the sol-
vent. Superimpose both the diagrams and study the effect of addition of aqueous CaCL
solution on the separation.
 534 Introduction to Process Engineering and Design

Table 8.51 Vapour Pressure of Water over Aqueous Calcium Chloride Solution39

Temperature, 0C Calculated vapour pressure of water, torr

Strength of CaCl^ Solution, mass %
0 20 25 35

40 55.3 47.9 41.5 30.1

70 233.7 197.7 179.6 136.4
90 525.9 448.4 408.7 318.0
100 760.0 660.6 593.9 466.1
110 1074.6 905.9 841.9 629.5
120 1489.2 — — 886.6

(a) A feed consisting of 50 mass % ethanol under saturated liquid conditions is to be

distilled to give 99.8 mole % (99.92 mass %) ethanol as distillate and 0.1 mole %
ethanol in bottoms in the extractive distillation column. Using McCabe-Thiele tech-
nique and for R = 2 Rm, find the number of theoretical stages required for the
separation at 101.325 kPa and locate the feed stage.
(b) If the distillate quality is restricted to 96.0 mole % (98.4 mass %) ethanol for the
case (a), find the number of theoretical stages required for the separation and locate
the feed stage.
Solution:
Azeotrope contains 0.1057 mole fraction (0.0442 mass fraction) ethanol. Let suffix 1
represent ethanol and suffix 2 represent water.
At the boiling point of the azeotrope, r = 78.150C or r= 351.3 K,

1592.90
log/7vl =7.2371- = 2.0033
(7-46.95)

pvl = 100.763 kPa = 755.78 torr

From steam tables, pV2 = 43.93 kPa = 329.50 torr
7, =760/755.78 = 1.0056
72 = 760/329.50 = 2.3065
van Laar equations:

0.1057
In (1.0056) =A
Process Engineering Channel

0.8943 + 0.1057

0.8943
In (2.3065) = B
0.1057+0.8943
@ProcessEng

Solving by Mathcad,
A = 1.950 34 and B = 0.9329
Using values of A and B, t-x-y data can be generated in an analogous manner to the
IPA-water system (Example 8.14). When use of aqueous CaClj solution (25 mass %) is
considered, /?u2will be replaced by i.e. vapour pressure of water over the aqueous
 Process Design of Distillation Columns

solution. For this purpose a graph of pV2 vs temperature can be plotted and pV2 values are
read at the required temperature.
Sample calculations for xl = 0.9 and Xj = 0.1:
7, = 1.004 98 and y2 = 2.318 96
Assume t = 78.20C or 7 = 351.35 K.
pv] = 757.22 torr
pv2 = 254.6 torr against p^ = 330.15 torr
p = Zxr yr pvi
= (0.9 x 757.22 x 1.004 98) + (0.1 x 254.6 x 2.318 96)
= 684.89 + 59.04 = 743.93 torr ^ 760 torr
Revise r = 78.80C or 7= 351.9 K.
pvl = 775.49 torr
pV2 = 260.8 torr
/? =761.9 torr ~ 760 torr
7! = (0.9 x 775.49 x 1.004 98)/760 = 0.923
Similarly t-x-y data are generated for ethanol-water-solvent system. Both t-x-y data
are presented in Table 8.52 and Fig. 8.50(a).

Table 8.52 Vapour-Liquid Equilibrium for Ethanol-Water System at I atm

Without solvent, mole fraction ethanol With solvent, mole fraction ethanol
0
In Liquid In Vapour Boiling point. C In Liquid In Vapour Boiling point, 0C
x y t x y t
0 0 100.0 0 0 107.0
0.025 0.2503 92.8 0.025 0.298 97.7
0.05 0.365 88.8 0.05 0.4234 92.95
0.1 0.468 85.0 0.1 0.531 88.35
0.2 0.542 82.3 0.2 0.6026 85.1
0.3 0.578 81.2 0.3 0.638 83.75
0.4 0.6096 80.35 0.4 0.668 82.7
0.5 0.647 79.65 0.5 0.703 81.8
0.6 0.693 79.05 0.6 0.745 80.9
0.7 0.75 78.6 0.7 0.7945 80.05
0.8 0.817 78.25 0.8 0.8513 79.3
0.8943 0.8943 78.15 - azeotrope — — —
Process Engineering Channel

0.96 0.953 78.1 0.9 0.921 78.8

1.0 1.0 78.1 1.0 1.0 78.1

Case (a):
Refer Fig. 8.5()(b), xD = 0.998, zF = 0.2811 (or 0.5 mass fraction) and xw = 0.001
Xr)
—= 0.2005
Rm +1
@ProcessEng

Km = 3.98
R = 2 Rm = 2 x 3.98 = 7.96
x
r>
=0.1114
R+l
Total 29 theoretical stages are required for the separation and the feed will be introduced
on 14lh stage.
 Introduction to Process Engineering and Design

1.0
-y
y
p = 101.325 kPa /
0.9
y
y //
y /S
0.8 y yy
y
y yy /Azeotropic point
y
Curve with 25% CaCl2 solution—n ,, =
y = 0.8913)
0.7

0.6 y
y
No solvent
/
/
^ 0.5 /
/
/
/
0.4 /
/
/
0.3 / /
/ /
/ /
I/
0.2 U—
1/

0.1

0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
x
Fig. 8.50(a) Vapour Liquid Equilibrium Curves for Ethanol Water System with and without
Aqueous Calcium Chloride Solution (25 mass%)

Case (b):
For xD = 0.96, the graph [similar to Fig. 8.50(c)] was redrawn and following data were
collected.

=0.2701
Rm+\
Process Engineering Channel

Rm= 2.554
= 2x2.554 = 5.108
X r\
-44— =0.1572
R+l
With these value of R, number of theoretical stages were calculated to be 17 and the
feed will have to be introduced on 14lh stage.
@ProcessEng

Required number of theoretical stages for both the cases were found using McCabe-
Thiele diagrams [Figs 8.50(b) and (c)]. However, it is recommended to recalculate the
requirement by tray-to-tray calculations for actual process design.
Note: It may be noted that single stage extractive distillation (ED) column is adequate
to produce ethanol with 99.8 mole % purity while in most ED systems, two columns
are required for the same degree of separation. Boiling point elevation at atmospheric
 Process Design of Distillation Columns 537

1.0

p = 10 1.32 5 kl
0.9
-1$ V
V
Oi
V- S s y
v- v' //
0.7 TV s /
/>V
--- /
/ //
0.6 /
// / /
9-1 IIC
f X / /
^ 0.5 /
/
T! / /
/ 1.0
/ / /
0.4 t
1 y/ / /Ass
1 / /
0.3 1 / A /
1 / / / / <yy
7*- 0.95
0.2 y '\S/SS
x/f /
—>■ // 'Xs/
+1 XXS /
i //
JlL. y
-/
R * I nt
Det ail 'A' 0. )5 XD 01
y
0
o\ 0.1 0.2 ^0.3 0/ 0.5 06 07 08 0.9 /^f o
x 0 001
w - Z p= 0.2811 xD = 0.998

Fig. 8.50(b) Extractive Distillation with Aqueous Calcium Chloride Solution (25 mass %)

pressure (at the bottom of the column) is just 70C. Also this ED system calls for 50%
or less energy than the conventional ED columns.
Presence of high chlorides means corrosive nature of the aqueous system. The col-
umn, reboiler and concentrator should be built with material of construction, resistant
to chlorides. Special stainless steel, such as Ti stabilized SS 316-L or high nickel alloy,
could be used for such corrosive service. Circulation pumps of Alloy-2() could be
used. However, cost of such materials of construction is higher than that of normally
Process Engineering Channel

used materials. Nevertheless, overall operating cost of the ED system with aqueous
CaC^ solution will be less than the conventional ED system.
Results of Case (a) and Case (b) indicate that the ED column will be more than 70%
taller in Case (a). Also reflux ratio of Case (a) is nearly 55 % more than Case (b). Both
these factors call for higher investment and higher energy consumption for Case (a).
Distillate of Case (b) contains 4 mole % (1.6 mass % or 16 032 ppm or 12 650 mg/
@ProcessEng

L) water. To dehydrate ethanol further, three options are shown in Fig. 8.49. In a con-
ventional manner (Option I), distillate with 4 mole % water will be distilled in another
column to yield the azeotrope at the top (to be recycled) and anhydrous ethanol at the
bottom. In Option II, part of the vapour from the ED column will be fed to a
pervaporation unit. Here again, contaminated water (with some ethanol), removed in
the membrane unit, can be recycled to the feed of the ED column. Drying of the distil-
 Introduction to Process Engineering and Design

1.0

p 10 1.32 5 kl'a z
0.9 >
V

0.8 /
'/
' /
0.7
---
/
- 7"— y
--- / /
0.6 /
/ /
/
/ q-\ ne
^ 0.5 X /
/ s
/ /
/ 1.0
/
0.4 y
1
11 / / /
1
■Vn 0.3 / / /y /
r / / 0.95
+I i / /
0.2 i /
Xj,
/ /
R*\ i rf
0.1 //
/ // Del ail 'A' 03)5 1. 0

0 /
0\ 0.1 0.2 ^).3 0.4 0.5 0.6 0.7 0.8 0.S 1.0
.XW= 0.001 _ Zn^o.. x
zf=0.2811 ^ xD = 0.960

Fig. 8.50(c) Extractive Distillation with Aqueous Calcium Chloride Solution (25 mass %)

late from ED column by molecular sieves is shown as Option III. All three options are
well proven in the industry and the selection should be made on the basis of minimum
total operating cost. Please refer Sec. 8.8.3 for detailed discussions on various options.

8.9 ENERGY CONSERVATION IN DISTILLATION

It was stated earlier that distillation is the most widely used separation technique
Process Engineering Channel

in chemical process industries but energy consumption in distillation is relatively

high. Hence saving of energy in distillation operation is important for lowering
overall cost of process plant. This aspect is also becoming important in biotech-
nology routes.
For saving the energy in distillation systems there are two options.
(i) Make the distillation more energy efficient; either by design or by operat-
ing the column more efficiently.
@ProcessEng

(ii) Replace the distillation partially or completely by a new separation tech-

nique.

8.9.1 Energy Efficient Distillation by Design

To decrease the energy consumption of distillation various design options can be

considered
 Process Design of Distillation Columns

(a) Optimum design of the system

(b) Heat integration
(c) Use of high efficiency trays or high efficiency packings
(d) Advanced process control
(e) Use of thermally coupled distillation columns
(f) Use of heat pumps (ejector/thermocompressor).

(a) Optimum Design of System

Process engineers have a general tendency to overdesign the system but at the
expense of energy. For example, very high purities are specified for the distillate
or bottom product which may not be warranted. At times, solvents are recycled in
the system and very high purity may not be required. By designing the system for
the desired purity only, reflux ratio can be trimmed thereby energy consumption
can be reduced. In Sec. 8.7.2, a case of extractive distillation of cyclohexane and
benzene mixture was discussed. As cyclohexane is a product, its purity of 99.3%
was specified as a distillate from the first column. However, since benzene is a
reactant which is to be recycled for further conversion to cyclohexane, its purity
of 85% was specified as a distillate from the second column. If benzene purity of
over 99% is specified, second column will be much taller with high reflux ratio,
resulting in high energy consumption in the reboiler. Take another example of
ethanol-water mixture. When ethanol is a desired product for mixing with petrol,
very high purity of ethanol will be needed.
For heterogeneous azeotropic distillation, first column is used as a concentra-
tor to produce distillate of near azeotropic composition. Subsequently two more
columns are required for separation of the components. Cho and Jeon have
proved after rigorous simulation by varying design parameters that while sepa-
rating aqueous IPA solution, the first column (the concentrator) should be
designed to produce distillate containing 38.7 mole% IPA (and not the azeotrope)
which should be subsequently processed in a two-column system to dehydrate
IPA. This design is claimed to consume lowest energy for the entire distillation
system.
Knapp and Doharty37 have proposed a two-column system (and not three col-
umn system) for concentrating dilute aqueous ethanol solution (containing just
Process Engineering Channel

4.2 mole % ethanol) from fermentor by adding approximately 0.043 kmol ac-
etone per kmol feed and applying pressure swing distillation technique. This
system is claimed to consume much less energy than conventional system.
Several such distillation case studies can be cited from the literature in which
it has been demonstrated that by careful selection of process parameters at the
design stage and the right technique, substantial energy savings can be achieved
in operation. However, most energy efficient design could be expensive from
@ProcessEng

equipment cost point of view. Nevertheless, energy saving outweighs capital cost
in most cases.

(b) Heat Integration

Heat integration is low risk technology and it results in substantial energy saving.
Reboiler of distillation column can act as a cooler for other unit. For example in
 Introduction to Process Engineering and Design

acetaldehyde plant, exhothermicity of the reaction is removed by circulating satu-

rated liquid leaving from the bottom of distillation column in lubeside of shell
and tube type reactor. Liquid is vaporized and vapour is sent back to the distilla-
tion column. Thus reactor act as a reboiler for the distillation column. An addi-
tional reboiler is provided for the distillation column for supplying the balance
heat (vapour) to the column.
Similarly overhead condenser can act as a heater or reboiler for other unit.
Overhead vapour of distillation column can be partially used as heating medium
of reboiler of other distillation column. This can be achieved conveniently with
an ejector as discussed in Sec. 8.7.1 (f).
In Sec. 8.7.3, it was seen that pressure swing distillation technique offers an
opportunity for thermal integration of condensers and reboilers of two columns
as they operate at different temperatures.

(cj Use of High Efficiency Trays or High Efficiency Packings

Number of equilibrium stages of existing distillation column can be increased by

replacing sieve trays or bubble cap trays with high efficiency packings or trays.
For the fixed extent of separation, increase in number of equilibrium stages re-
duces reflux ratio and consequently reduces reboiler energy. Other advantage of
using high efficiency packings (such as structured packings) or high efficiency
trays (modified sieve trays) is to increase in capacity of the distillation column.
Disadvantage of this replacement is higher cost of structured packings or of high
efficiency trays. Generally savings in energy cost outweigh the cost of high effi-
ciency packings/trays.
Example40: Replacement of sieve trays of 400 mm diameter distillation column
of styrene plant by a packed column, packed with structured packings, resulted
in saving of energy consumption by 17.7%. This column was operating at its
capacity of 24 500 kg/h of styrene. Its feed composition was 54% ethyl benzene
and 46% styrene (by mole), distillate composition was 96.9% ethyl benzene and
residue composition was 99.7% styrene (by mole). After replacement of sieve
trays by a packed column with structured packings, reflux ratio was reduced
from 7.3 to 5.8 and reboiler energy was reduced from 1605 kJ/kg of styrene to
1321 kJ/kg of styrene. In this modification, feed flow rate and purity of products
were kept same.
Process Engineering Channel

(d) Advanced Process Control

Plant operators normally operate the distillation columns with a sufficient safety
margin by achieving actual compositions of distillation products which are better
than specifications. Operating a distillation column in this manner requires extra
reflux and energy, but some margin is necessary so that the plant operator can
cope with process upsets and other problems. The 'safety' margin is smaller in
@ProcessEng

the plants which are properly designed and operated.

Installation of advanced process control systems based on accurate analytical
sensors, reliable control loop hardware and intrumentation and good process
models increases confidence in operators. In many instances, this added confi-
dence translated to a reduced margin of 'safety', reflux ratio and reboiler energy.
 Process Design of Distillation Columns

Example40: A conventional distillation column was used for separating a binary

mixture of propane and proplyene. Feed composition was 73% propylene and
27% propane (by mole). Required purity of top product was 99.7 mole % propyl-
ene for which reflux ratio was 13.5. With a sufficient margin conventional distil-
lation column was operated with excess reflux ratio of 15.5 to get the purity of
propylene of 99.9 mole % instead of the required purity of 99.7 mole %. After
installation of distributed control system (DCS) on this column more accurate
control of the purity of propylene at 99.7 mole % could be achieved which re-
duced energy consumption up to 13.5%. However, from a practical stand point,
operators cannot control product purity precisely at required composition in the
conventional system.

(e) Use of Thermally Coupled Distillation41

In the separation of multicomponent mixture (more than 2), thermally coupled

distillation columns require less energy and fixed cost as compared to conven-
tional distillation of multicomponent mixture. To understand this consider the
separation of a ternary mixture having components A, B and C by distillation. A
is the most volatile component and C is the least volatile component. Component
B is having intermediate volatility. Conventional methods for separating the ter-
nary mixture by distillation is either via direct sequence or indirect sequence, as
shown in Figs 8.51 (a) & (b).

A
A, B, C
>-
A

>-B
A. B
A, B, C
B,C
Process Engineering Channel

(a) Direct sequence (b) Indirect sequence

Fig. 8.51 Multicomponent Distillation in Sequence

@ProcessEng

For the given ternary mixture, selection between these two conventional
arrangement of distillation column depends on composition of the ternary mixture,
relative volatilities, latent heats of vaporization, boiling points, heat sensitivities,
etc. Compared to these conventional arrangements of distillation columns
thermally coupled distillation columns require less energy consumption and fixed
 Introduction to Process Engineering and Design

capital investment. For the separation of the same ternary mixture of A, B and C
by thermally coupled distillation, two types of arrangement are possible, as shown
in Figs 8.52 (a) and (b).

*—1—►A >-A

A. B
A, B, C ^B A, B, C

B,C H

^B

^ C

(a) Thermally coupled side (b) Thermally coupled side

column rectifier column stripper

Fig. 8.52 Thermally Coupled Distillation Columns

In thermally coupled side column rectifier, vapour stream is withdrawn from

the stripping section of main column and is sent for rectification in side column
where an overhead condenser is provided. Liquid stream from the bottom of side
column is sent back to the main column.
In thermally coupled side column stripper, liquid stream from the main col-
umn is withdrawn and is sent to side column for stripping where reboiler is pro-
vided at bottom. Vapour stream from side column is sent back to the main col-
umn.
Selection between these two arrangements depend on concentration profile of
intermediate component B. If concentration of component B is maximum at any
point of stripping section of the main or upstream column, then side column
rectifier is selected. By withdrawing a side stream from the point at which the
concentration of B is maximized, the distillation of B from either C or A is made
Process Engineering Channel

much easier.
Side rectifiers and side strippers can be cost-effective on any ternary separa-
tion where less than half of the feed leaves in middle product or where relatively
low purity of middle product is acceptable. Compared to conventional column
arrangements side stripper or side rectifier can reduce the energy consumption
up to 50%. Saving in fixed cost is also achieved because thermally coupled distil-
@ProcessEng

lation columns avoid the use of one condenser or reboiler and require reduced
column diameter or fewer stages for at least one column. Concept of thermally
coupled distillation is also applicable to any pseudoternary systems—i.e.
multicomponent mixtures requiring separation into three products. Hence it is
applicable to the distillation of any mixture of more than two components.
 Process Design of Distillation Columns

Refer Example 8.7 in which separation of fatty acids from a mixture is dealt.
Such a system can be considered for thermal coupling. In this case thermally
coupled side column is recommended.
In a petroleum refinery, this technique is extensively practiced to produce dif-
ferent cuts (products like kerosene, naphtha, petrol, etc.) from crude by having
number of side stream rectifiers and strippers.
As an alternate to the thermally coupled columns, a novel idea in design of
tray type distillation column is to have partitioned distillation column (Ref. 42)
(also called a divided-wall column or Petyluk column) for multicomponent sys-
tem. In such a column, a vertical baffle is placed (Fig. 8.53). which separates the
feed location from that at which the intermediate boiling product is withdrawn.
On the feed side of the partition, separation is achieved between the light (A) and
heavy (C) fractions while the intermediate boiling fraction (B) is allowed to mi-
grate to top and bottom sides of the partition. On the otherside of the partition,
the light fraction is washed down, thereby intermediate boiling fraction (B) of
desired purity is withdrawn. Such a column is larger in diameter than the other-
wise required two columns but overall capital and operating costs are signifi-
cantly (up to 30%) lower. Process design of such columns is quite complex and is
not available in open literature.

A B

A, B, C
B

C B
Process Engineering Channel

■►C
Fig. 8.53 Partitioned Distillation Column
@ProcessEng

(f) Use of Heat Pumps in Distillation

Steam ejectors have been used in limited distillation applications as inexpensive

heat pumps. An ejector uses high pressure fluid to entrain low pressure fluid.
Steam ejectors can be operated in different ways.
 | 544 Introduction to Process Engineering and Design

Simplest way to use an ejector is to operate with live steam. Figure 8.54 shows
the proposed arrangement. Part of the top vapours are compressed in an ejector
utilizing live (fresh) steam as motive fluid. Two or more ejectors can be used in
parallel to improve flexibility. Use of such an ejector system requires that (i) top
product is water and (ii) temperature difference between the bottom and top of
the column is low. Hydrogen peroxide-water distillation column can be fitted
with a live steam ejector.

B
D

Fig. 8.54 Ejector System with Live Steam as the Driving Medium43
(Reproduced with the Permission of Gul Publishing Co.. USA)

Figure 8.55 is a capacity ratio curve for the thermocompressor (ejector), oper-
ating with saturated steam at 20.7 bar g.
In Fig. 8.56, a system is shown in which top vapour product is used as a mo-
tive as well as entrained fluid. In this case, it should be possible to heat the top
product to a substantially higher temperature and pressure than the column's op-
erating conditions. Also the temperature difference between top and bottom of
the column should be low. Ethyl benzene/styrene splitter can be fitted with such
Process Engineering Channel

an ejectors system. A 225 x 106 t/a styrene monomer plant when operated with
such an ejector system reduced steam and cooling water requirements by 25%
and 32%, respectively. Capital investment for the modifications is expected to be
repaid in less than 18 months. Acetic acid-water, ethylene glycol-water systems
can also be operated in this manner.
In a third alternative, bottom product can be used to generate motive fluid, for
@ProcessEng

the ejector (Fig. 8.57). Part of the top vapours is condensed in a heat exchanger
with bottom product which operated under reduced pressure (say sub-
atmospheric). High pressure bottom product vapour provides the driving medium
for the ejector. For this system to operate satisfactorily, three conditions need be
satisfied, (i) It should be possible to heat the bottom product to a substantially
higher temperature and pressure than the operating conditions of the column.
 Process Design of Distillation Columns 545

r
'.5

m 6
3 to
X)
iT r
b 5
'Si
<D
i-— .
a. 4
<u Uq,
o '<>
c Pr.
Ssbre
Q Oa
O.S

(atn} 0s
Ph eric)

0.15 0.2 0.3 0.4 0.5 0.6 0.8 1.0 1.5 2.0 3.0 4.0
kg suction steam / kg motive steam

8.55 Capacity Ratios of Steam Jet Thermocompressors Operating with Saturated 20.7 bar g
Motive Steam
(Courtesy: Mazda-Croll Reynolds, Ahemedabad)

©-^VP-1

un
CEED E-3
E-2 CW

T- >'

Ejector

E-
Process Engineering Channel

C- E-4 W >'
r
Fresh
Steam

P-l Cond.
@ProcessEng

P-2
Fig. 8.56 Ejector System with Use Top Product as the Driving Medium43
(Reproduced with the Permission of Cul Publishing Co.. USA)
 Introduction to Process Engineering and Design

VP-l

3 E-3
t-2 t CW f BR

E-l

► ^ ■<
^ P-3
C-l

Ejector E-4
Fresh
steam V-l

Cond.

P-l ►B

P-2

Fig. 8.57 Ejector System with Bottom Product as the Driving Medium43
(Reproduced with the Permission of Cul Publishing Co.. USA)

(ii) Top product is not suitable for compression with the ejector, (iii) Temperature
difference between bottom and top of the column is low. Alcohol (methanol or
ethanol)—water distillation column can be fitted with such an ejector system.
Innovative flow sheets were presented as Fig. 8.54, Fig. 8.56 and Fig. 8.57 for
use of an ejector for energy conservation. Process engineer should therefore always
look for innovative designs which are technically feasible and select the best
option based on all aspects, including operational convenience.
It may be noted that in all the applications, it is necessary to have low tempera-
ture difference between top and bottom products of the column. Also the ejectors
should be large in size so that with low differential pressure between motive and
entrained fluids is permitted. In Figs 8.54, Fig. 8.56 and Fig. 8.57, number of
Process Engineering Channel

peripheral equipments are shown which require substantial capital expenditure.

Because of these reasons, ejector installation is of lesser interest for the smaller
columns. However, when large distillation column and substantial energy input
are required, use of ejector(s) could prove economically viable. (Ref. 43)
In Fig. 8.54, live steam is used for compressing the overhead vapours in an
ejector to the reboiler for its use as heat transfer medium. As an alternate to the
ejector, a vapour compressor (Ref. 44) can be used to compress the overhead
@ProcessEng

vapours (Fig. 8.58). The compressor could be a radial or an axial-flow

turbocompressor or a screw compressor, driven directly or via gear box by an
electric motor or a steam turbine. For overhead vapour having low molar mass
(such as water), compression is rather restricted up to 10 bar. For high molar
mass vapours, multistage compressors can be used to compress them up to 80
 Process Design of Distillation Columns

Vapour
compressor
& Reflux
Prime ©
Trim cooler
mover
condenser
Auxiliary
reboiler
Main
—© reboiler >

-4 B
Fig. 8.58 Distillation Columns with Direct Vapour Compressor44
(Reproduced with the Permission of Chemical Engineering by Access Intelligence. USA)

bar. For partial load operation, the compressor should have a variable speed or
kick-back arrangement, Performance of Vapour Recompression System (VRC)
is measured by calculating the ratio of reboiler duty (kW) to the power consump-
tion (kW) of the compressor. This ratio is called Coefficient of Performance (COP)
and typical value ranges from 6 to 15. Although VRC system can be used for any
distillation column on technical ground, it is favoured in the following cases due
to the economic factors.
(a) When reboiler duty is high (> 2 MW), VRC system is promising.
(b) Lower temperature rise across the compressor is preferred.
(c) When chilled water or brine is used to condense overhead vapours in the
condenser, use of VRC system is advantageous.
(d) Columns that separate products with low separation factors require larger
number of stages and high reflux ratio. Such columns are most suitable for
adoption of VRC sytem. Separation of propylene-propane, ethylene-ethane,
ethyl benzene-xylene, Ao-propanol-water (refer Example 8.17), etc. are
the systems which can benefit significantly by adoption of the VRC system.
In a typical case, 60% (by mass) fso-propanol feed (balance water) is distilled
to achieve azeotrope (87.5% Ao-propanol) with bottom product containing 15%
Process Engineering Channel

fvo-propanol. When overhead azeotropic mixture is compressed and used as a

heating medium in the reboiler, coefficient of performance in excess of 10 could
be achieved.
Where low cost heat or free waste energy is available for use in the reboiler,
VRC system is not recommended. Also when the column is operated under high
vacuum (>710 torr), VRC is not economical because compression ratio becomes
@ProcessEng

high.
One more option for reducing energy consumption in distillation is to adopt
heat pump with an auxiliary heat transfer medium (Ref. 45). In Fig. 8.59, distilla-
tion column with auxiliary heat transfer medium is shown. In the overhead con-
denser, vapours are condensed by evaporating the auxiliary medium. A compres-
sor compresses auxiliary medium vapours. In the reboiler, auxiliary medium
 Introduction to Process Engineering and Design

Main condenser or
> auxiliary heat
transfer medium evaporator
-*-*«

-*-D

Vapour
>, compressor

Trim
mover condenser
Auxiliary
reboiler

Main reboiler or
auxiliary heat
transfer medium condenser
Fig. 8.59 Distillation Column Heat Pump with Auxiliary Heat Transfer Medium45
(Reproduced with the Permission of Chemical Engineering by Access Intelligence, USA)

vapours are condensed and liquefied medium is recycled back to the overhead
condenser through an expansion valve, thus completing the cycle.
Typical auxiliary heat transfer media are refrigerants. Water (R-718), ammo-
nia (R-717), R-134a, R-22, R-502, etc. can be used for the purpose. Among
these, water (R-718) has many advantages over others. Water is chemically and
thermally stable. No negative environmental effect in case of leakage, no special
material of construction is required, cheap, high heat transfer co-efficients and
high latent heat of vaporization are chief factors that favour its selection. Per-
formance of heat pump with auxiliary medium is measured by Rankin coefficient
of performance. Generally, COP of water is higher than that of other refrigerants.
Considering capital investment for the auxiliary heat-transfer medium recycle
system and larger condenser and reboiler (as compared to conventional system),
Process Engineering Channel

heat pump system with auxiliary medium is cost effective when reboiler duty is
high (say > 2 MW). In this case also when close boiling components are to be
separated, the heat pump is economical. Separation of p-xylene and ethyl ben-
zene mixture and styrene and ehtyl benzene mixture can be good examples of the
system. For a 225 000 t/a styrene monomer plant, COP of heat pump with water
as auxiliary medium could be in excess of 5.5.
@ProcessEng

Example 8.19
A distillation column is to be designed for aromatics separation. Material balance around
the column is fixed and compositions of various streams are given below.
 Process Design of Distillation Columns 549 j

Table 8.53 Composition of Distillation Column Streams

Component Composition, mole %

Feed Distillate Bottoms

Benzene 2.2 22.8 0.

Toluene 7.4 72.2 0.5
Ethyl benzene 43.4 5.0 47.5
Styrene 47.0 0 52.0

Feed flow rate is 70 kmol/h as saturated liquid. Column must be operated under vacuum
to avoid thermal cracking and polymerization.
It is planned to use a heat pump (similar to one shown in Fig. 8.59) for the system.
Refrigerant R-134a (1,1,1,2-tetrafluoroethane) is to be used as an auxiliary heat trans-
fer medium. Bubble point of the distillate will be 120C in the overhead condenser and
accordingly operating pressure of the condenser will be fixed.
Determine the required number of theoretical stages for the desired separation. Also
find the location of the feed stage. Based on NTS, fix the height of packed bed, packed
with fibreglass reinforced plastic (FRP) Pall rings of 25 mm size. Assume pressure drop
in the column to be 0.04 atm and calculate the operating pressure of the reboiler. In the
reboiler, compressed R-134a vapour will be condensed.
Assume approach of 10oC in the condenser and the reboiler for effective heat transfer.
Calculate heat duties of the condenser and reboiler and the circulation rate of the refrig-
erant. Consider ideal behaviour of all liquid and gaseous mixtures.
Solution:
Bubble point of distillate: 120C
Considering ideal VLE,
pvi = p, (A)
xDB = 0.228, a-dt = 0.722 and a-deb = 0.05

Table 8.54 Antoine Constants13

Component Antoine Constants

A B C
Benzene 14.1603 2948.78 -44.5633
Process Engineering Channel

Toluene 14.2515 3242.38 -47.1806

Ethyl benzene 6.0821 1424.3 -59.95
Styrene 14.3284 3516.43 -56.1529

In pv = A for benzene, toluene and styrene (B)

(T + C)
@ProcessEng

and log p., = A for ethyl benzene (C)

{T + C)
where, pv is in kPa and T is in K.
At r= 12 + 273 = 285 K,
pVR = 6.659 kPa, pVT = 1.8547 kPa and pVEB = 0.567 kPa
 Introduction to Process Engineering and Design

Operating pressure of the condenser,

p, = 0.228 x 6.659 + 0.722 x 1.8547 + 0.05 x 0.567 = 2.8857 kPa
Pressure drop in the column = 0.04 atm = 4.053 kPa
Operating pressure at the bottom of the column, p, = 2.8857 + 4.053 = 6.9387 kPa
This pressure (p't) will fix the bubble point of the liquid in the reboiler.
ZxWiPVi=p', (D)
By trial and error, bubble point is to be fixed satisfy Eq. (D).
At rB = 62.50C, TB = 335.5 K
pVB = 55.9708 kPa,
Pw = 20.2005 kPa, pVEB = 8.1878 kPa and pvs = 5.7 kPa
Zxwi pvi = 0.005 x 20.2005 + 0.475 x 8.1878 + 0.52 x 5.7

= 6.954, close enough to 6.9387 kPa.

In this example, toluene is the light key component and ethyl benzene is the heavy key
component.

Table 8.55 Relative Volatilities

Component oc.top zz ' bottom

Py/ik Pv/l/c
Benzene 11.744 6.836 8.96
Toluene (LK) 3.271 2.467 2.8407
Ethyl benzene (HK) 1 1 I
Styrene 0.625 0.6962 0.6596

FUG method:
Minimum number of theoretical stages can be found, using Fenskey's equation.
"/ \ / \ ■
XLK XHK
log
yXfiK ) D - XlK j B _
^n = (8.23)
10gocLK

0.722 V 0.475
log
Process Engineering Channel

0.05 A 0.005
K,= = 6.919, say 7
log (2.8407)

Underwood method:

_ ^ *,/
= !-<? (8.15)
-1?
@ProcessEng

8.96x0.022 2.8407x0.074 1x0.434 0.6596x0.47

■+ + + =0
8.96 -1? 2.8407 - 1-tf 0.6596 -1?
Solving by Mathcad,
= 2.4052
Also tfe {1, ...,2.8407)
t? = /?m+l
 Process Design of Distillation Columns 551

x X
i iD
(8.14)

8.96x0.228 2.8407x0.722 1x0.05

H 1 = /C, + 1
8.96 - j) 2.8407 - iJ
For = 2.4052, Rm = 3.9856
Gilliland correlation:

N - Nin 1 + 54.41// V-l

f(N) = = 1 - exp. x (8.25)
N+l 11 + 117.21// 0.5

K-
where. ¥= (8.26)
R+\

Table 8.56 Evaluation of Parameters

R ¥ f(N) N

4.5 0.093 53 0.5603 17

6 0.2878 0.39 12
7 0.3768 0.3288 10.76
0.446 0.2819 10
0.50144 0.2483 9.53

Referring Table 8.56, R = 8 is considered optimum and required number of theoretical

stages are 10.
Feed tray location can be determined by Kirkbride equation,

X X
JV,^ W_ HK. F LK. II
log = 0.206 log (8.27)
D X
LK. F X
HK,D

For determining W and D, material balance calculations are to be carried out.

Overall material balance:
F = D+W
Process Engineering Channel

10 = D + W (E)
Benzene balance:
0.022 xF = 0.228 xD + OxW
0.022 F = 0.228 D (F)
Solving Eq. (E) and Eq. (F),
D = 6.7544 kmol/h and W = 63.2456 kmol/h
@ProcessEng

N.. 63.2456 0.434 ^[0.005

x
log = 0.206 log
\ Nki / 6.7544 0.074 I 0.05

= 0.8839
N.
 Introduction to Process Engineering and Design

Nr + Ns = 10
Ns = 5.308. Let Ns = 6
Therefore, sixth stage from bottom will be the feed stage. Pressure drop per stage is
calculated to be 0.405 kPa which is reasonable.
Heat duty of condenser, fa
fa =(R+ I) D Aav
Using Watson equation, latent heats of vaporization for the components of distillate are
calculated as under at I20C.
Ab = 34 252.6 kJ/kmol,
At = 38 452.8 kJ/kmol and
Aeb = 42 497.0 kJ/kmol
Aav = IA,. ■ y,- = 0.228 x 34 252.6 + 0.722 x 38 452.8 + 0.05 x 42 497.0
= 37 697.3 kJ/kmol distillate
4,(, = (8 + 1) x 6.7544 x 37 697.3 = 2291 603.8 kJ/h = 636.56 kW
Let t = 120C be the reference temperature
Hd = 0, Hf) ■ D = 0
Refer Table 6.29 of Chapter 6.
At T = 335.5 K

335.52 - 2852
Hw = -17.712 (335.5 - 285) + 1054.193 x lO"3

, 335.53 - 2853 N

- 1838.075 x lO"6

335.54 - 2854
+ 1694.332 x I0"9

= 9240 kJ/kmol mixture

Hw W = 9240 x 63.2456 = 584 389.3 kJ/h = 162.33 kW
Feed is saturated and hence enthalpy of feed at its bubble point is to be calculated.
At bubble point.
Process Engineering Channel

X
i Pv
=1^=1
p'i
Since feed is nearly in the middle of the column, assume average pressure at the feed
point

2.8857 + 6.9387
P," = = 4.9122 kPa
@ProcessEng

0.022 pVB + 0.074 Pyj + 0.434 pVFB + 0.47 pvs = 4.9122

This equation can be solved by trial and error calculations. At = 490C (322 K),
pVB = 34.18, pVT = 11.6264, pVEB = 4.435, pvs = 3, all in kPa
Xxi pvj = 4.947, close enough to 4.9122 kPa
Refer Table 6.30 of Chapter 6.
 Process Design of Distillation Columns

3222 - 2852
Hp = -16.023 (322 - 285) + 1030.422 x lO"2

J3223 - 2853
- 1809.476 x 10-6

3224 - 285
+ 1693.124 x 10-6

= 6561.5 kJ/kmol feed

■ F = 6561.5 x 70 = 459 305 kJ/h = 127.6 kW
Assume 5% heat loss to surrounding and no heat of mixing.
(pp =((t)c + HD-D + Hw ■ W — HF ■ F) 1.05
= (636.56 + 0 + 162.33 - 127.6) 1.05 = 704.85 kW = 2537 460 kJ/h
Approach for heat transfer in the overhead condenser and reboiler is 10oC. Since
distillate bubble point is 120C, auxiliary heat transfer medium (R-134a) should evapo-
rate at 20C. Similarly in reboiler, boiling takes place at 62.50C and hence R-134a va-
pours are to be condensed at 72.50C.

Table 8.57 Properties of R-134a 23

Temperature Pressure. Enthalpy, kJ/kg Vapour,

0
C bar a Liquid Latent Vapour Cp/Cv
2.0 3.150 (satd.) 202.68 197.07 399.75 1.182
72.5 22.385 (satd.) 308.57 120.42 428.99 1.653
130.0 23.0 — — 500.00 —

(Reference state: Enthalpy of saturated R-134a at 0oC = 200 kJ/kg)

In the condenser, R-134a liquid from the reboiler (at 72.50C) will be flashed to 20C
and vapours will be produced.
Heat, taken up in condenser,
H, = 399.75 - 308.57 = 91 kJ/kg
tpc
Evaporation rate of R-134a, mR = —
H
i
Process Engineering Channel

mR = 2291 603.8/91 = 25 182.5 kg/h

These vapours will be superheated by 10oC before taking to the compressor to avoid
any liquid carryover. This can be done be exchanging heat with liquid from reboiler.
However, for the present, this difference is neglected. Vapour at 3.15 bar a will be com-
pressed to 23 bar a.
Overall compression ratio = 23/3.15 = 7.302
Since this is high, it will be compressed in a 2-stage compressor.
@ProcessEng

Compression ratio in each stage = ^1302 = 2.702

Vapours will be compressed from 3.15 bar a to 8.511 bar a in the first stage, cooled
suitably and compressed to 23.0 bar a in the second stage. Its temperature is expected to
be 130oC.
Heat, given up in the reboiler, Ho = 500 - 308.57
'= 191.43 kJ/kg
 Introduction to Process Engineering and Design

Heat available, <p'B = 25 182.5 x 191.43 = 4820 686 kJ/h = 1339.1 kW

Since is much higher (by 90%) than a trim condenser will be needed to take
care of the excess heat load. This heat (low level) can be utilised to heat the feed or some
other stream in the plant. In addition, during start-up, overhead condenser will not have
any heat-load but reboiler will have to be commissioned. Therefore, an additional auxil-
iary reboiler will be needed with some other heat source, say with low pressure steam for
the start-up. It can be seen that adoption of heat pump system will thus call for a number
of additional equipments.
Notes:
(i) Since required number of equipments are many more than for the convention
distillation system, initial investment will be substantially high.
(ii) Operating pressure of the reboiler shell will be 23 bar a. This will call for thick
shell, calling for higher investment.
(iii) Adequate instrumentation and controls (I&C) will be needed for the refrigerant
circulation system in addition to the I&C for distillation system, calling for addi-
tional investment.
(iv) Cost of Refrigerant R-134a is much higher than conventional utilities. Enough
care is required to prevent its leakage from the circulation system.
Fixed, and variable cost for driving the compressor and extra cost of the heat pump
system should be carefully weighed against savings in normal utilities, used in the
conventional distillation system. Also skilled personnel will be required for operating
the integrated system.
Heat pumps save energy in distillation but at a definite cost. Careful economic evalu-
ation is therefore necessary before its implementation.

8.9.2 Efficient Operation of Distillation Columns

Existing distillation columns can be operated in such a manner that substantial

energy can be saved.
(a) Many distillation columns are operated to excessively purify the products
which might call for high reflux ratio and hence high reboiler duty. This
should be avoided by having adequate I&C.
(b) Damaged or worn column internals can be costly. Over a period of opera-
tion, the column internals may get damaged. For example, in bubble cap
Process Engineering Channel

columns, top nut may loosen and cap may open up, in valve trays, valves
may flyoff, in packed columns, ceramic packings may crumble, scaling on
trays may take place over a period of operation, etc. Due to similar reasons,
the existing columns should be opened for inspection periodically and pre-
ventive maintenance should be carried out. Such preventive maintenance
practice will pay rich dividends in terms of energy saving in operation.
@ProcessEng

8.9.3 Replace the Distillation Partially or Completely by

New Separation Technique

Replacing of distillation by supercritical extraction or by reactive distillation can

result in significant energy savings. The same is discussed in Sec. 7.6 and Sec 8.6
of this text. Similarly energy savings can be achieved by replacing distillation
 Process Design of Distillation Columns

partially or completely by new separation techniques like membrane separation

techniques (revese osmosis, pervaporation, membrane distillation, membrane re-
actor, etc.), molecular sieve adsorption, crystallization, etc.
Example40: Conventionally absolute alcohol (ethanol) is separated from
azeotropic mixture of ethanol-water (95.6% ethanol, 4.4% water by mass) by
azeotropic distillation using benzene or cyclohexane as an entrainer. This con-
ventional method uses three distillation columns and requires very high energy
consumption. One of the new methods for separating the same mixture is by
o
Pressure Swing Adsorption (PSA) which utilize 3 A molecular sieves. Molecular
sieve adsorption consumes less energy and eliminates the use of the entrainer.
Benzene is a proven carcinogen and therefore an air pollutant. For the production
of 3400 kg/h of fuel-grade ethanol, installation of molecular sieve—pressure
swing adsorption system instead of azeotropic distillation unit allows a reduction
in energy consumption of boiler from 2257 to 147 kW. But this new technique
requires additional electrical energy in the amount of about 100 kW to drive the
vacuum pumps and other equipments for the PSA unit. The use of benzene or
cyclohexane as entrainer is eliminated.
For the separation of same azeotropic mixture, pervaporation can also be used.
For the production of fuel grae ethanol with the same rate; 3400 kg/h, installation
of pervaporation allows a reduction in energy consumption of boiler from 2257
to 264 kW. But fresh electrical energy, equivalent to 150 kW is required to drive
the vacuum pumps and other equipments for the pervaporation unit.
/.w-propyl-alcohol (1PA) is yet another application for which pervaporation
can be used. IPA forms an azeotrope with water having composition of 87.9%
(by mass) IPA. Dehydration of IPA azeotrope with zeolite membrane is commer-
cially carried out.

Table 8.58 Comparison of Pervaporation and Adsorption with Distillation

Parameter Distillation Pervaporation Adsorption

Capacity, m3/d 3 to 30 0.5 to 30 10 to 30

Feed water content, % 5-95% 0.5 to 30 0.05 to 5
Process Engineering Channel

Product water content. mg/L <2000 < 1000 < 100

Operating cost High Low Medium
Capital cost Low Medium Medium
Floor space requirement Large Small Large
Safety Medium High Medium
Environment friendliness Low Excellent Medium
Ease of installation Medium Easy Medium
@ProcessEng

Operation Skilled Easy Skilled

Turndown capability Medium Excellent Poor
Start-up and shut-down time Long Short Long
Maintenanace requirements High Low High
Availability/Uptime Medium High Medium
Flexibility Limited Excellent Medium
 Introduction to Process Engineering and Design

Freeze crystallization is yet another technique which can be used for recovery
of organic species, such as acetic acid, acrylic acid, etc. from very dilute solu-
tions with 75 to 90% energy reduction as compared to conventional distillation.
Heist46 has given a process flow sheet for 95% recovery of acetic acid from 1%
aqueous solution (by mass) by freeze crystallization. Normally 1% solution could
be considered as effluent with high non-biodegradable COD and its disposal will
be a serious threat to the industry. Recovery will turn effluent disposal problem
into an economical proposal by adoption of freeze crystallization.

Exercises

8.1 Fill the gaps in the following crossword puzzle.

nnnnnnnnnrnnnsannnr

■■■■■nnnnnnnnannrr

"nHnnnnnnnBnnBnnnr

nnpnnnnnnnBnnBnanr

□□■□■■■■■■■■nnnann

HBBBnnnnnnannianBnn

nnBHBnnnnnnBBBBBBB

Mbbbbbbbbb nn Bnann

nr ■ r "nnriBnBnn
Process Engineering Channel

nmnBnnnnnnnriBnnnn

"1 BBBBrnnBBBBBBB

nnnannnnnnnnB Inn

nnnnnnnBBBBBBBnnnn
Fig. 8.60 Crossword Puzzle47
@ProcessEng

(Reproduced with the Permission of Dr. Ming Tham of School of Chemical Engineering and
Advanced Materials. University of Newcastle upon Tyne. UK)
KEYS:
Down:
I. A conduit that directs liquid from one tray to another.
4. Liquid carried by vapour up to the tray above.
6. This is determined by the amount of material going through the column.
 Process Design of Distillation Columns

9. Brought about by excessive vapour flow.

14. An alternative to the use of trays or plates.
15. Made-up of the two components.
Across:
2. A liquid mixture which when vaporized produces the same composition as the
liquid.
3. A type of tray used in distillation/absorption.
5. An equipment used to cool vapours, coming off the top of the column.
7. Distillation operations require lots of this.
8. Operation performed by the top section of the column.
10. Product stream taken off the top of the column.
11. Liquid that is fed back to the top of the column.
12. An equipment used to raise vapour.
13. A mixture that is to be separated.
16. Expansion of liquid due to vapour or gas.
17. Operation performed by the bottom section of the column.
18. Ensures that there is sufficient liquid on a distillation tray.
19. Caused by low vapour flow.
20. Product stream taken off bottom of the column.
8.2 Distillation column is used to separate aqueous solution of dimethyl formamide
(DMF). Determine the following based on given data.
(a) Minimum reflux ratio.
(b) Number of theoretical stages required for desired separation for R = 2 Rm.
(c) Overhead condenser duty.
(d) Reboiler duty.
Data:
(i) Feed composition: 20% by mass DMF, Molar mass of DMF = 73.1 kg/kmol
Feed is saturated liquid. Feed flow rate =100 kmol/h
(ii) Distillate composition: 99% water (by mass).
(iii) Residue composition: 99% DMF (by mass).
(iv) Operating pressure at top: 650 ton- vacuum or 110 torr a.
(v) For vapour pressure data refer Table 8.59.
(vi) Properties of DMF
Latent heat of vaporization A = 576.85 kJ/kg at the top most temperature of
distillation column
Specific heat CL = 2 kJ/(kg ■ 0C)
Process Engineering Channel

8.3 NRTL parameters for dimethyl formamide (1) and water (2) are as follows:
ti2 =bl2/RT, t2i = b2i/RT, R = 8.314 kJ/(kmol • K)
6I2 =-267.667, 62l =470.31
\2
G Gn 1,2
In 7, =xl (8.112)
X*-) O9 1 J u + x,G 2
@ProcessEng

G G-,,
21 r'■21
In 72 = x (8.113)
x2+ x.O ( X, + A'2 G21 )

where, Gi2= exp (-»= r,-,), G-,, = exp (-<* 121)

oc = 0.277
Operating pressure in distillation column = 650 torr vacuum
 Introduction to Process Engineering and Design

Table 8.59 Vapour Pressure Data ofDMF and Water

Temperature pv of DMF pv of water

o
c torr torr

53.7 18 110
60 26 149.38
70 42 233.7
80 65 355.1
90 100 525.76
92 110 567
100 165 760

Solve Exercise 8.2 considering nonideality of DMF-water system. To find the VLE
data following equation can be used.

8.4 In the production of chloromethanes, a saturated liquid mixture consisting of 60%

methyl chloride, 28% methylene dichloride, 9% chloroform and 3% carbon tetra-
chloride (by mass), is sent do distillation section for the separation of pure prod-
ucts. In first distillation column 99.9% (by mass) pure methyl chloride is separated
as top product. Determine the followings for this distillation column.
(a) Operating pressure of distillation column.
(b) Minimum reflux ratio by Underwood's method.
(c) For R = 3 R,,! calculate the numer of theoretical stages required for desired
separation.
(d) Determine the tower diameter of distillation column, selecting sieve tray tower
for the same.
Feed is a saturated vapour mixture and its flow rate is 5000 kg/h.
8.5 Determine the minimum reflux ratio and number of theoretical stages required for
Process Engineering Channel

reflux ratio, R = 2 Rm, for the following given separation by.

(i) Ponchon - Saverit method based on given H-x-y data and equilibrium x vs y
data, given in Table 8.60.
(ii) McCabe - Thiele method using phase equilibrium data x vs y, given in
Table 8.60.
(iii) McCabe - Thiele method by using vapour-liquid equilibrium data x vs. y, which
can be derived by using following equation.
@ProcessEng

yiP,= YiPviXi
where, ^ = Activity coefficient can be determined by van Laar equa-
tions. van Laar constants A = 1.978, B = 1.401.
In Table 8.60, "1" stands for ethanol and "2" for benzene.
 Process Design of Distillation Columns

Data:
(i) Feed: 100 kmol/h contains 10% ethanol and 90% benzene (by mole)
Feed is saturated liquid
(ii) Distillate; It contains 44% ethanol (by mole)
(iii) Residue: 99.9% benzene (by mole)
(iv) VLB and enthalpy data at 760 torr:

Table 8.60 VLE Data and Enthalpy Data for Ethanol-Benzene System

Mole Fraction of ethanol Temperature Enthalpy of mixture, kJ/kmol

x. yf /, oc Hg
0 0 79.7 -15 870 19 090
0.01 0.075 78.0 -15 910 18 380
0.023 0.150 76.0 -16 120 17 580
0.045 0.217 74.0 -16410 17 170
0.095 0.305 71.0 -17 170 16 540
0.200 0.395 69.0 -18 630 15 910
0.300 0.425 68.4 -20 050 15 740
0.447 0.447 68.2 -22 150 15 570

8.6 1000 kg of feed containing 30% by mass ethylene glycol and 70% by mass water, is
to be separated in batch distillation with rectification column. Bottom product must
contain 98.8% by mass of ethylene glycol. Composition of distillate should remain
constant throughout the batch distillation. Desired composition of distillate is 98%
by mass water.
(a) Design the rectification column.
(b) Determine the operating (actual) reflux ratio vs time data.
(c) Compare the resulting data of this example (batch distillation with rectifica-
tion with the resulting data of Example 8.12 (simple batch distillation).
Operating pressure in rectification column is 30.4 kPa a (maximum). Vapour liquid
equilibrium data for ethylene glycol-water system at 30.4 kPa a are given in Exam-
ple 8.12.
8.7 Chloroform and methanol form a minimum boiling azeotrope at 101.325 kPa and
53.50C containing 65.17 mole % chloroform. Using van Laar equations, generate
r-x-y relationship and plot y vs x diagram.

Table 8.61 Antoine Equation Constants13

Process Engineering Channel

Component Antoine Constants Normal Boiling Point

A B C at 101.325 kPa,
0
C
Chloroform 14.5014 2938.55 -36.9972 61.15
Methanol 16.4948 3593.39 -35.2249 64.65
@ProcessEng

Antoine equation: In p..=A

(T + C)
where, pv = Vapour pressure, kPa
T = Saturation temperature, K
8.8 Formic acid and water form a maximum boiling azeotrope at 101.325 kPa and
107.1oC, containing 43.3 mole % water. Using van Laar equations generate t-x-y
relationship and plot y vs x diagram.
 560 Introduction to Process Engineering and Design

Table 8.62 Antoine Equation Constants13

Component Antoine Constants Normal Boiling

A B C Point at 101.325 kPa
o
c
Formic acid 6.7067 1699.20 -12.45 100.8
Water 7.0436 1636.90 -48.25 100.0

Antoine equation: log /?„ = A

(7' +C)
where, pv = Vapour pressure, kPa
T = Saturation temperature, K
8.9 In Example 8.19, refrigerant R-134a was selected. Consider use of refrigerant R-
22 (chlorodifluoromethane) or refrigerant R-717 (ammonia) as alternate auxiliary
heat transfer mediums. Properties of R-22 and R-717 are given below.

Table 8.63 Properties of R-2223

Temperature Pressure Enthalpy, kJ/kg Vapour

o
c bar a Liquid Latent Vapour Cp/Cv

2.0 5.315 (satd.) 202.36 202.65 405.01 1.296

72.5 31.51 (satd.) 296.44 118.15 414.59 2.147
130.0 32.0 — — — 478.7 —

(Reference state: Enthalpy of saturated liquid at 0oC = 200 kJ/kg.)

Assume 10oC approach in the overhead condenser and reboiler for R-22.

Table 8.64 Properties of R-71123

Temperature Pressure Enthalpy, kJ/kg Vapour

0
C bar a Liquid Latent Vapour Cp/Cv

7.0 5.54 (satd.) 232.55 1236.31 1468.86 1.415

72.5 35.06 (satd.) 558.85 923.10 1481.95 1.834
130.0 35.50 — — — 1692.34 —
Process Engineering Channel

(Reference state: Enthalpy of saturated liquid at 0oC = 200 kJ/kg.)

Ammonia evaporator is normally a flooded one. Therefore, assume approach of

50C in the overhead consdenser and approach of 10oC in the reboiler.
Calculate required circulation rates of R-22 and R-717 for the same heat duties.
Also review the performances of all three auxiliary heat transfer mediums and criti-
cally evaluate system requirements, including environment friendliness.
8.10 Extractive distillation of 50 mass % aqueous /.vopropyl alcohol (1PA) is to be car-
@ProcessEng

ried out with the help of aqueous 35 mass % CaCR solution. Vapour pressure data
of aqueous calcium chloride solution are given in Table 8.51. Calculate t-x-y data
for the system and plot the equilibrium fx, y) curve.
8.11 In a refinery, a gas stream, having composition 6.84% ethane, 40.81% propane,
9.70% /-butane and 42.65% n-bulanc (by mole), is to be fractionated at a rate of
300 kmol/h in a column to separate LPG fraction48. Feed gas is compressed, cooled
 Process Design of Distillation Columns

and flashed in the fractionating column at 9.7 bar a and 450C. Overhead vapours
from the column are taken to partial condenser from which Cj and Cj-fractions are
separated in gaseous form. Composition of the gaseous stream from the condenser
is 28.25% ethane, 68.55% propane, 1.6% /-butane and 1.6% /j-butane (by mole).
Flow rate of overhead vapour is 68.52 kmol/h. It leaves the condenser at 9.4 bar a
and 20oC. Saturated liquid from the condenser at 20oC is recycled as reflux to the
column at the rate of 1.2 kmol/kmol vapours separated. Pressure drop in the over-
head condenser may be considered negligible (<10 kPa) for calculation purpose.
Bottom residue (LPG fraction) is removed from the reboiler at 10 bar a. Use Fig.
6.20 for dew point and bubble point calculations.
(a) Make complete material balance calculations of the column.
(b) Determine minimum reflux ratio.
(c) Determine number of theoretical stages for the reflux ratio 1.2 kmol/kmol and
the stage at which the feed should be introduced by FUG method.
(d) In Tables 8.65 and 8.66, enthalpies of liquid and gaseous hydrocarbons are
given. Using these values, calculate the heat duties of the overhead condenser
and the reboiler.
(e) Considering low temperature of the vapours (20oC), leaving the overhead con-
denser, use of ammonia (R-717) is proposed as an auxiliary heat transfer
medium in the overhead condenser and the reboiler. Evaporation of ammonia
at 150C in the overhead condenser and condensation of ammonia at 650C in
the reboiler are fixed as design parameters. Consider conditions of ammonia at
the compressor discharge as 30 bar a and 1250C. Properties of ammonia are
given in Table 8.67. Calculate ammonia circulation rates, required in the over-
head condenser and the reboiler. Comment on the results.

Table 8.65 Enthalpy of Liquid Hydrocarbons at Saturated Conditions49 (in kj/kmol)

Temperature, K Ethane Propane /-Butane «-Butane

290 304 1918 2521 2525

300 1840 3112 3939 3941
305.34c 4154
310 — 4353 5397 5391
320 — 5650 6896 6878
330 — 7015 8442 8404

""Critical temperature of ethane

Process Engineering Channel

Reference state: Enthalpy of saturated liquid hydrocarbon at 0oC = 0 kJ/kmol

Table 8.66 Enthalpy of Gaseous Hydrocarbons49 (in kj/kmol)

Hydrocarbon Temperature, K Pressure, bar

@ProcessEng

Ethane 1 2 3
280 11 700 11 630 11 560
300 12 730 12 680 12 620
320 13 820 13 770 13 720
330 14 380 14 330 14 280
(Contd.)
 562 Introduction to Process Engineering and Design

Table 8.66 (Contd.)

Hydrocarbon Temperature K Pressure, bar

Propane 568

290 17 785 17 615 —

300 18 585 18 425 18 105
320 20 205 20 085 19 825
340 21 885 21 785 21 565

/-Butane 0.1 0.5 1.0

280 21 935 21 835 21 695
300 23 825 23 745 23 635
320 25 825 25 755 25 665
340 27 935 27 875 27 805

a-Butane 0.1 0.5 1.0 2.0 3.0

280 23 545 23 425 22 845 — —

300 25 475 25 385 25 255 24 505 —
305 — — — — 25 245
320 27 515 27 435 27 325 27 105 26 875
340 29 655 29 575 29 485 29 305 29 105

(Reference state; Enthalpy of saturated liquid hydrocarbon at 0oC = 0 kJ/kmol)

Table 8.67 Properties of Ammonia (R-717)23

Temperature. Pressure Condition Enthalpy. kJ/kg C/C,,

o
c bar a Liquid Vapour

15 7.286 Saturated 270.2 1475.9 1.438

65 29.476 Saturated 518.6 1487.1 1.748
125 30.0 Superheated — 1695.0 —

(Reference state: Enthalpy of saturated liquid ammonia at 0oC = 200 kJ/kg)

8.12 Tetrahydrofuran (also known as 1,4-epoxy butane; formula: C^HgO) is widely used
as a solvent and also as a reaction medium in chemical industry. Typical THE recov-
ery method involves adsorption on activated carbon, followed by steam stripping of
Process Engineering Channel

the bed. Resulting THF-water mixture is a dilute aqueous stream of THE which is
required to be separated in pure components for reuse of THE.
THE forms a minimum boiling azeotrope at 63.50C, containing 5.3% by mass of
water at atmospheric pressure. For the separation of THE from the mixture, pres-
sure swing distillation process50 is used. Basic flow sheet of the process is shown in
Fig. 8.61.
In the first column, THF-water mixture, containing 0.06 mole fraction THE is
@ProcessEng

fed. Distillate D, from the top has near azeotropic composition (0.805 mole frac-
tion THE). Reflux ratio of 0.26 kmol/kmol distillate is maintained in this column.
Bottom product of the first column is pure water (in which THE content is
1 x 10~6 mole fraction).
Distillate D, is fed to the second column, operating at 7.908 bar a. At this pres-
sure, THF-water mixture forms a minimum boiling azeotrop at 1360C, containing
 Process Design of Distillation Columns 563

i—
tD
c5
5
X
f—

5
u

u
•o

as cu
10
:x: I
u_
«m gory/. = £

>. c
o
as U

Q
>nr uo
r, c
•C 5
m
as
g
ai a
o
• -1-H
4—^
uijb t = ld NO
NtS
CO
—
i\ >> M "o
iZ S
u a
-o
>- 0)
rI t/1
X
Process Engineering Channel

g
a. Q.
X
1)
- 4J
o X. in
a
o
■a
is
e
OJ
-a CJ
@ProcessEng

c
O
o
S sO
<iS ^2 o (U
x:
o U
o
o in <
Uh m
jj
o
Z
 Introduction to Process Engineering and Design

12% by mass water. Distillate from the top has near azeotropie composition
(0.65 mole fraction THF) and is recycled to the first column. Bottom product from
the second column is pure THF (in which water content is 1 x 1()~5 mole fraction).
Reflux ratio in the second column is maintained at 0.65 kmol/kmol distillate.
Assume that van Laar correlations represent non-ideality of THF-water mixtures
in both the columns. Carryout tray-to-tray calculations for both the columns and fix
feed locations of F and Di for fresh feed rate of 1000 kmol/h.

Table 8.68 Properties of THF and Water

THF Water

Normal boiling point, "C 66 100

Freezing point, 0C -108.5 0
Density, kg/L 0.889 1.0
0
Antoine constants Temperature range, C
60-150 60-70 70-80 80-90 90-100 100-150
A 6.995 15 7.1365 7.1095 7.0883 7.0733 7.0436
B 1202.29 1695.2 1678.9 1665.9 1656.4 1636.9
C 226.25 -42.75 -44.15 -45.35 -46.25 -48.25
Average latent
heat of vaporization.
A, kJ/kmol 27 901 41453

Antoine equations: log P.. = A for THF

v
U + C)

log p' = A for water

(7" + C)
where, pv = Vapour pressure of THF, torr
pf = Vapour pressure water, kPa
t = Saturation temperature, 0C
T = Saturation temperature, K
8.13 A plant employs a batch reactor with refluxing arrangement (with cooling water) to
manufacture amino resins. One of the products is melamine-formaldehyde (MF)
resin. Melamine, aqueous formaldehyde (37% by mass) and n-butanol are the chief
Process Engineering Channel

reactants. Phosphoric acid (98% pure, 0.5% by mass) is used as a catalyst. In a

typical batch of 4 kL, average consumptions for a specific grade MF resin are re-
ported to be 0.58 t n-butanol, 0.215 t melamine and 0.24 t formaldehyde (100%)
per t MF product. Etherification and esterification reaction take place in the reactor
at atmospheric pressure and in the temperature range of 90 to 105oC. Product water
and water of aqueous formaldehyde solution are removed from the reactor in the
form of an azeotrope with n-butanol. Condensed azeotrope separates in two layers;
@ProcessEng

compositions of both the layers depend on the temperature. Butanol rich layer is
recycled and aqueous layer at 40oC is collected in a separate tank for recovery of
/(-butanol by distillation. In the batch, 100% excess n-butanol is used for comple-
tion of reaction. At the end of reaction excess n-butanol is recovered by distillation.
Batch is normally completed in 8 to 10 h.
 Process Design of Distillation Columns

Product contains up to 1.25% formaldehyde and 2 to 2.5% n-butanol (by mass).

Since the reaction takes longer time, substantial crosslinking takes place which is
more than desired.
It is decided to adopt a continuous system for production of MF resin as the
product demand has shot up. For this purpose, process research was carried out in
the laboratory. Use of strong cation exchange resin (up to 4% by mass), suitable for
continuous operation at 140oC, was made as a catalyst instead of phosphoric acid.
Results of the 20-litre flask showed that while consumptions of the reactants were
nearly same as that of batch process (for the same grade), better quality product was
produced in 3 h. MF resin so produced had less croslinking and low formaldehyde
(< 0.5%) content. Further experiments with a glass column, packed with glass Raschig
rings, confirmed that 3 theoretical stages for stripping are required for achieving
bottom product (MF resin) with less than 1 % n-butanol (by mass). Data on n-butanol-
water azeotrope are covered in Sec. 8.7. Consider: (i) Excess n-butanol will be just
sufficient to remove water in the form of the azeotrope and (ii) Residence time of
reaction mass in the distillation column in contact with the resin will be 3 h.
Based on above information, develop a process flow diagram for the reactive
distillation system for continuous production of MF resin along with desired instru-
ment and control system with technical reasons. Consider whether pilot plant stud-
ies are required to implement the project commercially. Also study the advantages
and disadvantages/limitations of proposed reactive distillation system over the batch
system.

References

1. Treybal, R. E., Mass Transfer Operations, 3rd Ed., McGraw-Hill, 1980.

2. Ludwig, E. E., Applied Process Design for Chemical and Petrochemical Plants,
Vol. 2, 3rd Ed., Gulf Publishing Co., USA, 2002.
3. Smith. B. D., Design of Equilibrium Stage Processes, McGraw-Hill, USA, 1963.
4. Gmehling and Onken, DECHEMA Chemistry Data Series, DECHEMA, Germany
Vol.1, 1997.
5. Chu, J. C. Wang, S. L.. Levy, S. L. and Pual, R., Vapour—Liquid Equilibrium Data,
Edwards Inc., USA., 1956.
6. Hala, E., Wichterle, I. and Lineks, J., Vapour—Liquid Equilibrium Data Bibliogra-
phy, Elsevier, The Netherlands, 1976.
Process Engineering Channel

7. Hala, E., Wichterle, I., Polak, J. and Boublik, T., Vapour-Liquid Equilibrium Data
at Normal Pressure, Pergamon, UK. 1968.
8. Gmehling, J., Azeotropic Data, 3 Vol., Wiley-VCH, Germany, 2004.
9. Sinnott, R. K. Coulson and Richardson's Chemical Engineering, Vol. 6, Revised
2nd Ed., Asian Books Pvt. Ltd. 1988.
10. McCade, W. L., Smith, J. C., Harriott, P., Unit Operation of Chemical Engineering,
6th Ed., McGraw-Hill, USA, 2001.
@ProcessEng

11. King, C. J., Separation Processes, 2nd Ed., McGraw-Hill, USA, 1980.
12. Deshpande, P. B., Distillation Dynamics and Control, Arnold, USA, 1985.
13. Bhatt, B. I. and S. M. Vora, Stoichiometry, 4th Ed., Tata McGraw-Hill Publishing
Co. Ltd., New Delhi, 2004.
14. Perry, R. H. and Green D., Perry's Chemical Engineer's Handbook, 6th Ed., McGraw-
Hill, USA 1984.
 Introduction to Process Engineering and Design

15. Kroschwitz, J. I. (Ed.) Kirk and Othmer's Encyclopedia of Chemical Technology,

4th Ed., Vol. 5, John Wiley, USA, 1993. p. 175.
16. Kister, H. Z., Distillation Design, McGraw-Hill, USA, 1992.
17. Fair J. R., Chem. Engg., 70 (14), July 8, 1963, p. 119.
18. Van Winkle, M., Distillation, McGraw-Hill, 1967.
19. Billet, R., Distillation Engineering, Chemical Publishing Co., USA, 1979.
20. Mukherjee, S., Chem. Engg., 112 (9), 2005, p. 52.
21. Fischer, W.. Saminar on "Short Path Distillation", Mumbai, 1996.
22. Kukla, N., Chemical Plant Processing, 1996, p. 74.
23. Bhatt, B. I., Design Dalabook: Properties of Steam, Selected Refrigerants' n-Hexane
and Brines, CBS Publishers and Distributors, New Delhi, 2007.
24. Degarmo J. L., Parwleker V. N., Pinjala V, Chem. Engg., Progr., 86 (3), 1992,
p. 45.
25. Mahajani S. M., Kolah A. K., hid. Engg. Chem. Res., 35, 1996, p. 4587.
26. Grogins, Unit Process in Organic Synthesis, McGraw-Hill, USA.
27. Jacobs R., Krishna R., Ind. Engg. Chem. Res., 32, 1993, p. 1706.
28. Snessby M. G., Tade M. J., Datta R., Smith T. N., Ind. Engg. Chem. Res., 36, 1997
p. 1855.
29. Bhanvase, B. A., Y. R. Soman and R. V. Naik, Chem. Engg. World, 41 (2), p. 43,
2006.
30. Coates, J., Chem. Engg., 67 (10), May 16, 1960, p. 121.
31. Norman, W. S., Absorption, Distillation and Cooling Towers, Longmans, USA,
1961.
32. Cho, J. and Jong-Ki Jeon, Korean J. Chem. Engg., 23 (1), 2006, p. 1.
33. Mcketta, J. J. and W.A. Cunningham, Enculopedia of Chemical Processing and
Design, Vol. 5, Marcel Dekker, Inc., USA, 1977, p. 257.
34. Private Communication with Dr. Jen-Uwe Repke, TU Berlin, Germany.
35. Repke, Jen-Uwe and A. Klein, Proceedings of the 15th European Symposium on
Computer Aided Process Engineering, (Ed. L. Puigianer and A. Espuna), Elsevier
Science B.V., 2005.
36. Repke. Jen-Uwe, F. Eomer and A. Klein, Chem. Engg. & Tech., 28 (10), 2005,
p. 1151.
37. Knapp, P. J. and M. F. Doherty, Ind. Engg. Chem., Res., 31, 1992, p. 346.
38. Levy, S. G., D. B. Van Dongen and M. F. Doherty, Ind. Engg. Chem. Fundam., 24,
1985, p. 463.
39. International Critical Tables, 1st Ed., Vol. Ill, McGraw-Hill, USA, 1928, p. 292.
Process Engineering Channel

40. Humprey, J. L. and Seibert, A. F, Chem. Engg. Progr., 88 (3), March, 1992, p. 32.
41. Finn, A. J., Chem. Engg. Progr., 89 (10). October, 1993, p. 41.
42. H. Becker, S. Godorr, H. Kreis and J. Vaughan, Chem. Engg., 108 (1), January
2001, p. 68.
43. Meszaros, I. and A. Meili, Hydrocarbon Processing, 81 (3), March 2002, p. 51,
44. Meili, A. and A. Stuecheli, Chem. Engg., 94 (2), February 16, 1987, p. 133.
45. Meili, A. and A. Stuecheli, Chem. Engg. Progr., 89 (5), 1993, p. 49.
@ProcessEng

46. Heist, J. A., Chem. Engng., 86 (10), May 7, 1979, p. 72.

47. Private Communication with Dr. Ming Tham, University of Newcastle Upon Tyne,
UK.
48. Kaiser V. and J. P. Gourlia, Chem. Engg., 92 (17), August 19, 1985, p. 45.
49. Younglove, B. A. and J. K. Ely, J. Phy. Chem. Ref. Data, 16 (4), 1987, p. 577.
50. Samir, I., Abu-Elshah and W. L. Luyber, Ind. Engg. Chem., Process Des. Dev.,
24(1), 1985, p. 132.
 Chapter Cj

Process Design of

Absorbers

9.1 INTRODUCTION

Absorption is an important unit operation of chemical process industries. In

absorption a gas mixture (or a gas-vapour mixture) is contacted with a suitable
liquid called solvent to separate one or more components of the gas mixture by
dissolving them in the liquid. Hence, after the absorption, components of gas
mixture are transferred to the solution. Dissolved component in the solution can
be separated by distillation or stripping (reverse of absorption). For example, in
the manufacturing of synthesis gas for ammonia from the gas mixture containing
nitrogen, hydrogen, carbon dioxide and traces of other components, carbon dioxide
is removed or separated by absorption in elhanol amine solution. Then carbon
dioxide from the resulting solution is separated by stripping. "Absorber" and
"scrubber" are sometimes used as synonyms. Truly speaking, if a component of
the gas mixture, transferred to liquid, is a gas at operating conditions of mass
transfer, then it is called absorption. If a component transferred is vapour at
operating conditions then it is called scrubbing. Below critical temperature, a gas
is known as vapour (which could be saturated or superheated). For example,
separation of acetone vapour from air. Acetone vapour mixture in contact with
water as solvent is called scrubbing. Operating conditions of this scrubber is
Process Engineering Channel

atmospheric pressure and ambient temperature. Critical temperature of acetone

(Tc = 508.1 K) is well above the ambient temperature. Absorption or scrubbing is
chiefly carried out in a packed tower, although plate (tray) columns are not
uncommon. Various types of equipment used as absorbers or scrubbers are:
(i) Packed tower
(ii) Tray tower
@ProcessEng

(iii) Falling film absorber (Shell and tube heat exchanger)

(iv) Spray chamber
(v) Venturi scrubber
(vi) Stirred tank
 568 Introduction to Process Engineering and Design

9.2 CRITERIA OF SELECTION

9.2.1.1 In majority of applications, packed tower is selected because of the

following reasons.
(i) Tower diameter required for the majority of the applications is less than
0.75 m. Packed tower is generally cheaper than tray tower when tower di-
ameter is less than 0.75 m.
(ii) Many absorption or scrubbing systems are corrosive systems. For corrosive
systems plastic packed towers (for example FRP packed towers) with plas-
tic packing are cheaper than metallic tray towers.
(iii) In majority of absorption with chemical reaction systems, overall rate of
gas - liquid reaction is totally controlled by rate of mass transfer (i.e., rate
of chemical reaction > > rate of mass transfer). Packed tower provides
higher rate of mass transfer due to higher interfacial area of contact com-
pared to other equipments.
(iv) For the liquids having high foaming tendency and also for a heat sensitive
liquid, packed tower is a better choice than tray tower.
(v) For removing obnoxious gases from the vent gases or from the flue gases
by absorption, available pressure of feed gas, fed to absorber or scrubber, is
usually very low; close to atmospheric pressure. Hence, for such a case,
pressure drop in absorber is the main criteria for selecting the equipment.
Packed tower provides less pressure drop compared to a tray tower. Hence
for such applications, packed towers are preferred.

9.2.1.2 For removing sulphur dioxide (SO2) from boiler flue gases in large
scale plants, available pressure of flue gases is very low; close to the atmospheric
pressure. For this case, even packed tower is not suitable because pressure drop
offered by packed tower is normally greater than 100 mm WC. Normally for
such an application spray tower or spray chamber is used. Alternatively, a venturi
scrubber can be used which induces vacuum in the suction.

9.2.1.3 Tray towers are selected as absorber in the following cases.

(i) In case of exothermic absorption, it can be improved by providing external
Process Engineering Channel

cooling during absorption. Cooling coils can be more readily built into tray
towers and liquid can readily be removed from the trays to be passed through
coolers and returned, than from packed towers. Take for example absorption
of acetaldehyde from acetaldehyde vapour-gas mixture by using ethanol-
water solution as solvent. This absorption is exothermic and hence tray
tower with intermediate coolers is used as absorber. Similarly, absorption of
@ProcessEng

formaldehyde in water is exothermic which can be conveniently carried out

in a plate column. Refer Example 9.5 and Figs 4.2 and 4.7. Absorption of
carbon dioxide in ammonia plant is preferably carried out in a tray column
which is exothermic in nature, although packed columns are also in use.
 Process Design of Absorbers

(ii) For the absorption systems involving low liquid flow rate, tray towers are
preferred to get the better gas-liquid contacting efficiency. Low liquid rate
may lead to incomplete wetting of column packing in case of packed tower
and can give lower contacting efficiency.
(iii) If solids are present in liquid or gas then tray towers are preferred because
they permit easier cleaning.

9.2.1.4 For highly exothermic absorption, e.g. absorption of hydrogen chlo-

ride gas in water and absorption of ammonia gas in water, more efficient heat
removal system is required to get the higher efficiency and higher concentration
of solution. For such applications, falling film absorbers are used. These are shell
and tube heat exchangers, in which absorption is carried out inside the tubes
while cooling medium is circulated on shell side. Design of a falling film ab-
sorber is dealt later in this chapter (Example 9.4).

9.2.1.5 Venturi scrubbers are normally preferred for removing paniculate matter
from a gas stream as opposed to absorbing soluble vapours from vapour-gas
mixture. Venturi scrubber provides higher gas-liquid contact or higher absorp-
tion efficiency but at the expense of relatively large gas side and liquid side pres-
sure drops and consequently it requires higher power consumption.

9.2.1.6 Stirred tanks and sparged towers are preferred for slow gas-liquid re-
actions. Normally, in cases of absorption with chemical reaction, solvents or liq-
uid reactants are selected in such a way that they offer fast or very fast chemical
reaction with the solute gas. Hence, these equipments are normally not used as
absorbers.

9.3 DESIGN OF PACKED TOWER TYPE ABSORBER

Process design of packed tower type absorbers involve two major steps; (i) deter-
mination of tower diameter and (ii) determination of height of packing. Method
for determining tower diameter is same for all types of packed tower absorbers.
But methods for finding the height of packing are different for the following
cases.
Process Engineering Channel

(a) Physical absorption from dilute gas mixture in isothermal conditions

(b) Physical absorption from concentrated gas mixture in isothermal condi-
tions
(c) Physical absorption in non-isothermal condition. Example: absorption of
HC1 or NH3 in water
(d) Absorption with chemical reaction. Example: absorption of chlorine in so-
dium hydroxide solution
@ProcessEng

9.3.1 Packed Tower Type Absorber for Physical

Absorption

Example of an absorber for physical absorption from dilute gas mixture in

isothermal condition is the absorption of acetone vapour in water from air-acetone
 Introduction to Process Engineering and Design

vapour mixture containing less acetone (say 6%). Step wise design for this case
is as follows.
(i) From the given gas mixture data, find G], Gs, y] and F,.
where, G, = Molar flow rate of gas mixture, kmol/h
Gs = Molar flow rate of non solute gas mixture, kmol/h
yj = Mole fraction of solute in feed gas
GS=G] (1 -y,) (9.1)

G2,. L2
Gs /-s
x
yi 2
Y2 1*2

A
B
S
O
R
B
E
R

G\ Lx
L
Gs s
y\ x\
Y\ -Fi

Fig. 9.1 Variables Used for Material Balance and Design

Process Engineering Channel

Fi
l
-yi
Y] is the ratio of the moles of solute gas to the same of non-solute gas for incoming
gas,
Gj = G/l + F,) (9.2)
@ProcessEng

Decide the degree of absorption to be carried out in absorber, if it is not specified.

Find y2, F2 and G2.
 Process Design of Absorbers

=
where, J2 Mole faction of solute in outgoing gas mixture

is the ratio of the moles of solute gas to non-solute gas

(9.3)
where, G2 = Molar flow rate of outgoing gas mixture, kmol/h
If absorber is a pollution control tower then value of ^ or ^ is decided by
pollution control norms.
(ii) Select a suitable solvent. In the selection of solvent, the important properties
to be considered are solubility of solute gas in the solvent, volatility, cost,
corrosiveness, etc1. Solvent which reatcts with the solute by chemical reaction
provides high solubility. If recovery of solvent or solute gas is essential then
chemical reaction should be reversible. For example, for the absorption of CO2
gas, caustic soda solution provides higher solubility or absorbtivily than ethanol
amine solution. But in actual application ethanolamine solution is selected as
solvent rather than caustic soda solution because CO2 gas can be easily separated
from ethanolamine solution at higher temperture and lower pressure in a stripping
column while caustic soda solution does not easily release CC^gas in stripping
operation.
(iii) Find the gas-liquid equilibrium data. Draw the equilibrium curve in terms
of F vs X.
(iv) Find the minimum amount solvent required for the desired separation.
Minimum amount of solvent is the maximum amount of solvent for which infi-
nite number of equilibrium stages are required for the desired separation. In other
words, it is the maximum amount of solvent for which desired degree of absorp-
tion is not possible. Minimum amount of solvent, in physical absorption is deter-
mined by graphical method.
(a) In this method first draw the equilibrium curve V vs X.
(b) Mark (X2, Y2) point, where, X2 = ratio of the moles to solute to moles of
solvent for incoming solvent, Y2 = ratio of the moles of solute to nonsolute gas
for outgoing gas mixture.
(c) Draw the tangent starting from point (X2, Yj) and allow it to intersect with
horizontal line from Fj, if the equilibrium curve is concave upward [Fig. 9.2 (a)].
Process Engineering Channel

But if the curve is concave downward as shown in Fig. 9.2 (b), draw the line from
ant
(X2, F2) l j0'n it w
ith the point of intersection of equilibrium curve and hori-
zontal line from F,.
In any case intersection point is represented as (Xlm, Fj). Where X1(); is the
value of X, corresponding to minimum amount of solvent and X, is the ratio of
the moles of solute to solvent in outgoing solution.
@ProcessEng

(d) Write the overall solute balance equation

Lsw(Xiw-X2) = Gi(F1-F2) (9.4)
substitute the value of Xlm obtained from the graph and find the value of Lsm
from the above equation.
 572 Introduction to Process Engineering and Design

1 <jr2 y2)
c% -
X
(a) (b)

Fig. 9.2 Minimum Amount of Solvent

(e) Decide the actual molar flow rate of solvent; L^,. Ideally it should be optimum.
Optimum amount of solvent is the amount of solvent which gives minimum total
cost of absorption. Total cost includes fixed cost, operating cost, interest on fixed
capital, etc. At design stage, if it is not possible to find the optimum solvent flow
rate, then actual flow rate Ls should be the greatest of the following values.
Ls=1.5Lsm (9.5a)
1xp
(9.5b)
M
w
where, Mw = Molar mass of solvent
Certain minimum flow rate is required to facilitate the use of a centrifugal
pump.
^'Minimum wetting rate (MWR) is the liquid rate, required to form a liquid
film over all the packing. No hundred per cent reliable method is available to find
MWR. Some designers take minimum liquid rate for any tower packing as 7340
kg/(h ■ m2 of tower cross section)2. Packing wetting rates are related to packing
material surface

Table 9.1 Minimum Wetting Rate for Different Packings3

Surface Minimum wetting rate (MWR), m /(trr - h)

Process Engineering Channel

Unglazed ceramic 0.5

Glazed ceramic 2.0
Glass 2.5
Stainless steel 3.0
Carbon steel 0.7
Polypropylene 4.0
Poly vinyl chloride 3.5
@ProcessEng

Poly tetrad uoro ethylene (PTFE) 4.0

Morris and Jackson equation gives minimum solvent rate required in m /(h • m"
of cross section of tower) by following equation"'
Ls = MWR. a, (9.5c)
2 3
where, a, = Packing surface area per unit volume, m /m .
 Process Design of Absorbers

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Process Engineering Channel

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— CN m in, — cn r*-, m, JQ it <n r- CN in — cn m in, on
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@ProcessEng

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 574 Introduction to Process Engineering and Design

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Process Engineering Channel

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@ProcessEng

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 Process Design of Absorbers

Values of MWR in m2/h for rings less than 75 mm size is 0.08 and for packing
more than 75 mm size it is 0.12.
Kister has suggested values of MWR in m3/(m3 • h), 1.26 to 5.4 for random
packings and 0.252 to 0.504 for structured packing4.
(f) Find the value of -W based on overall solute balance.
Ls(Xx - X2) = G/F, - Y2) (9.6)
(g) Find the N0G or NOL.
where, N0G = Number of overall gas phase transfer units
Nol = Number of overall liquid phase transfer units
Height of packing required for the given absorption duty is determined by
using one of the following equations.
Z = Hqg -NQG W
or Z=HoLNoL (9.8)
If overall resistance to mass transfer is controlled by the gas film, then Eq. (9.7)
is used to find the packing height Z for the desired absorption duty. If the gas is
highly soluble in liquid (solvent), then major resistance to mass transfer is provided
by the gas film. For example HC1 (hydrogen chloride gas) is highly soluble in
water. Hence, in this absorption, over all resistance to mass transfer is governed
by hydrogen chloride gas film resistance. Another example of gas-film controlled
absorption is absorption of acetone vapour in water from air-acetone vapour
mixture. In the same case, if the concentration of solute gas in gas mixture is less
than 10% (by mole) then molar flow rate of gas can be assumed as constant and
height of packing (Z), is given by following equation.
y
G ' dy
Z = H0G-N00=--^ (9.9)
K a
G P y2 y- y'e

where, //oc = —2^- (9.10)

Kg ap

7 dy
and Nog= (9.11)

where, Gm = Molar flow rate of gas per unit cross sectional area, kmo]/(m2 • s)
Ka = Over all gas phase mass transfer coefficient, kmol/(atm • m2 • s)
a = Interfacial surface area per unit volume, m /nr (Ref. Table 9.2)
Process Engineering Channel

p = Operating pressure, atm

=
Hog Height of an over all gas phase transfer units, m
=
NoG Number of an overall gas phase transfer units
Nqgcan be determined by Eq. (9.11), for which area under the curve of l/(y -ye)
vs y within limits from ^ 1° I7] is determined. In the special case, if equilibrium
curve and operating line, both can be assumed as straight lines, V0G can be
@ProcessEng

calculated by equation4

x
^ _ mGm Vi ^ Gin
NoG= dr hm (9.12)
m(j'm V 4i / 3'2 Am
1-
L.n
where m is the slope of the equilibrium line and Gm/Lm is the slope of the operating
line.
 Introduction to Process Engineering and Design

If the overall resistance to mass transfer is controlled by liquid film then Eq.
(9.8) is used to find the packing height. If the solubility of gas in liquid phase is
very low then overall resistance to mass transfer is governed by liquid film resist-
ance. For example; (i) absorption of carbon dioxide gas (CO2) in water from CO2
rich gas mixture and (ii) absorption of dimethyl ether in water. In such cases
normally a chemical reagent is added into liquid phase which reacts with solute
gas and thereby increases the rate of mass transfer dramatically. For example, for
the absorption of CO2, potassium carbonate (K2CO3) or ethanol amine is added
into water to improve the rate of the absorption of carbon dioxide (CO2). In the
same case, if the concentration of solute gas in gas mixture fed to absorber is less
than 10% (by mole) or for the dilute system, molar flow rate of liquid can be
assumed as constant and height of packing required can be calculated by the
following equations.
Z=Hol-NOL (9-8)

where, HOL= ^ (9.13)

KlCIC,

and Nol=]-^- (9.14)

x2 Xe-X
where, Lm = Molar liquid flow rate per unit cross sectional area, kmol/(nr ■ s)
Nql = Number of overall liquid phase transfer units
Hqi = Height of an overall liquid phase transfer unit, m
Kl = Overall liquid - phase mass transfer coefficient, m/s
a = Interfacial surface area per unit volume m2/m3
C, = Total molar concentration, kmol/m3
X| = Mole fraction of solute in the liquid phase at the outlet from ab-
sorber
X2 = Mole fraction of solute in the liquid phase at the inlet to the
absorber
= Equilibrium mole fraction of solute in liquid phase

Nol can be determined by Eq. (9.14), for which area under the curve of —^—
Process Engineering Channel

xe- x
vs x within limits x, to ^ should be determined.
(h) Determination of Tower Diameter:
For packed tower type absorber, tower diameter is determined based on flood-
ing velocity. Actual velocity of gas through packed tower is kept about 60 to 70%
of flooding velocity. Recommended range of pressure drop for packed tower
type absorber is 15 to 50 mm water column per m of packing height depending
@ProcessEng

on the application. At the time of flooding, one of two conditions may occur;
(i) Liquid phase may occupy the entire cross section of tower. Continuous phase
of liquid body rises in the column. The change in pressure drop is very high with
only a slight change in gas rate, (ii) Phase inversion occurs and gas bubbles
through the liquid. Pressure drop rises rapidly as phase inversion occurs. To find
the tower diameter, at first the following factor is determined.
 Process Design of Absorbers

At- Pg
Flg = (9.15)
G
w V Pl
where, Lw = Mass velocity of liquid, kg/(m"" • s)
Gw = Mass velocity of gas, kg/(nr • s)
-j
pG = Density of gas, kg/nr
p, = Density of liquid, kg/m -
Using Fig. 9.3, corresponding value of K at flooding {KF) is determined. Actual
value of K is determined as follows.

0.40

0.20
Parameter of curves is pressure
'">1, / • drop in mm of walcr/m of
packed height
0.10 —J
*Su

51. \
X\\
v
•4.
0.020
'O ~JL4 \
\
0.010 V
\ \\
\ V \\
4.2
\ %

0.002

0.001,
01 0. 02 0. 04 0. 06 0.1 0 .2 0.4 0.6 1.0 2.0 4.0 6.0 10
Process Engineering Channel

'-km
Fig. 9.3 Generalized Flooding and Pressure-Drop Correlation for Packings3
(Reproduced with the Permission of McGraw-Hill Education. USA)

Let the actual velocity of gas through lower be 66% of flooding velocity.
K = (0.66)2Kf (9.16)
@ProcessEng

Corresponding value of pressure drop per m of packed height can be determined

by using Fig. 9.3.
A" is a function of G

K= (9.17)
PGPlS
 Introduction to Process Engineering and Design

where, Gw = Mass velocity of gas, kg/(nr • s)

K = Function of velocity of gas through tower
Pg Pl - Density of gas and liquid, respectively, kg/m3
j. \\/2
K ■ Pg Pl. g
G,„
W= (9.18)
2
Fp ¥ Ml
2
g = 9.81 m/s
Fp = Packing factor, m_1 (Ref: Table 9.2)
y/ = Ratio of density of water to density of liquid
/iL = Viscosity of liquid, m Pa • s (= cP)
(i) Determination of H0G or HOL:
Many different correlations are available to find out the height of transfer unit or
to find out the mass transfer coefficients. But, these correlations are not as reliable
as the same for finding the heat transfer coefficients. Hence, it is suggested to
find out the height of transfer unit of mass transfer coefficient by using the
correlation which is derived for the same or a similar system. But, if the correlation
for the same or a similar system is not available, then, use more than one
generalized correlations for finding the height of transfer unit iH0G or HOL) and
the maximum value obtained from the different correleations is considered for
finding the height of packing. Two generalized correlations are given as follows:
(a) Onda Takeuchi and Okumoto Correlation:3
Height of overall gas phase transfer unit HOG and height of overall liquid phase
transfer unit H0L are related with HG and /// by following equation.

Hog = Hg+ m—^-HL (9.19)

«ol = HG+ (9.20)

m
Gm

where, m is the slope of equil ibrium line, GJLm is the slope of operating line and
Gm and Lm are the molar flow rates of gas and liquid, respectively per unit cross-
sectional area of tower in kmol/(m2 ■ s). Height of gas phase transfer unit {HG) is
Process Engineering Channel

determined by following equation.

Gw
Hr= (9.21)
G
Kg ae pMg

and height of liquid phase transfer unit HL is determined by following equation

@ProcessEng

HL = —T (9,22)
k a
l e Pl
where, Gw = Superficial mass velocity of gas, kg/(s ■ rrr)
Lw = Superficial mass velocity of liquid, kg/(s • m2)
p = Operating pressure. Pa
 Process Design of Absorbers 579

M., = Molar mass of gas

• • • ^
pL = Liquid density, kg/nr
ae = Effective area for mass transfer, m2/m3
Kg = Gas phase mass transfer coefficient, kmol/(m2 s ■ Pa)
Kj = Liquid phase mass transfer coefficient, m/s
Effective area for mass transfer are is obtained by following equation

^ = 0.3l^-(Cfl,-^)0-392 (9.23)
a, r0.4

where, ae = Effective area for mass transfer, nr/nr

a, = Total area of packing, m2/m3 (Ref. Table 9.2)
gl = Liquid surface tension, m N/m (= dyn/cm)
Z = Packed height, m
CaL = Liquid capillary number = iuL Lw/(pL oy)
(dimensionless group) (9.24)
T,
pL = Density of liquid, kg/m
pL = Viscosity of liquid, mPa • s (= cP)

6 a,.
ReG - Gas Reynolds number - (9.25)
a
t He
Gw = Mass velocity of gas, kg/(nT s)
pG = Gas viscosity Pa • s
Gas phase mass transfer coefficient is determined by the following equation:
_ \0.7 / \l/3
kgrt Mg -2
= c, {a, dp) (9.26)
a, Dg ■ \ a, pa PG DC
where, KG = Gas phase mass transfer coefficient, kmol/(m s • Pa)
/^ = 8314 J/(kmol ■ K)
Dg = Gas phase diffusion coefficient, nr/s
T = Operating temperature, K
pG = Density of gas, kg/m3, dp = Packing size, m
C| = 2 for random packings of size less than 12 mm
Process Engineering Channel

= 5.23 for random packings of size more than 12 mm

Liquid phase mass transfer coefficient is determined by following equation.

\l/3 2/3 / >-0.5

( Pl AM Pl 0.4
Kl = 0.0051 {a, dp) (9.27)
v PL 8 aw PL Pl D,

pL = Liquid viscosity, kg/(m ■ s )

@ProcessEng

g = 9.81 m/s2
Lw = Mass velocity of liquid, kg/(m • s)
Dl = Liquid phase diffusion coefficient, nr/s
dp = Equivalent diameter of packing, m
 Introduction to Process Engineering and Design

aw = Wetted surface of packing, m2/m3

aw is determined by following equation.

\0.75
a.. o",C
= 1-exp -1.45 Re^1 Fr~m We0L2 (9.28)
a,

where, crc = Critical surface tension of the packing material, m N/m

(Ref. Table 9.3 )
gl = Surface tension of liquid, m N/m

K
Re, = Liquid Reynolds number = (dimensionless)

FrL = Froude number for liquid = L2ajip2L g) (dimensionless)

We, = Weber number for liquid = L~/(pL o, at) (dimensionless)

Table 9.3 Critical Surface Tension of Packing Materials3

Material of Packing a,., in N /m or dyn/cm

Carbon 56
Ceramic 61
Glass 73
Polyethylene 33
Polypropylene 33
Polyvinyl chloride 40
Steel 75

(b) Cornell's method

In this method height of overall gas phase transfer unit HOG or height of overall
liquid phase transfer unit HOL is calculated by the same equations Eq. (9.19) and
(9.20) that are used for Onda's method but HG and FIL are determined by the
following equations.
Height of gas phase transfer unit HG is calculated by following equations.
For Raschig rings and Pall rings,
Process Engineering Channel

0.017 ur D1 24
Z0'33 5c^"5
"g = (9.29)
Uv/i A/b)0'6
For saddle type packings.

0.029 y/ Dl 11
Z0,33 Sc? 5
: (9 30
Hg = ' >
@ProcessEng

05
(A,/i fif,)
where HG = Height of gas phase transfer unit, m

ScG = Gas phase Schmidt number = — (dimensionless)

Pgdg
 Process Design of Absorbers

• • /
Dg = Gas phase diffusion coefficient, m /s
pG = Density of gas, kg/m3
pG = Viscosity of gas, kg/(m • s) or Pa • s
D - Column diameter, m
Z = Packed height, m
Lw = Mass velocity of liquid, kg/(m2 • s)

v0.16
}h_
/.= with pw - 1.0 mPa • s
Pw

/ \l.25
Pw
fi = with pw = 1000 kg/m"
Pl

0.8

h= with (J,,, = 72.8 m N/m

v G, /
y/ = Correlation parameter can be obtained from Fig. 9.4 for various
types of random packings.
Height of liquid phase transfer unit is calculated by following equation.

0.5 ,0.15
<pc Pl
Hl = (9.31)
3.28 PlDL 3.05

where, /// = Height of liquid phase transfer unit, m

0 = Correlation parameter for a given packing, m (0 can be obtained
from Fig. 9.5)
C = Correlation factor for high gas rates which can be obtained from
Fig. 9.6
pL = Liquid viscosity Pa.s
P/ = Liquid density kg/m'
Dl = Liquid diffusion coefficient, m2/s
Z = Height of packing, m
In this method, if the column diameter (D) is greater than 0.6 m then take D = 0.6 m
Process Engineering Channel

for the calculation of HG.

(j) Design or selection of internals of packed tower:
Internals of packed tower are packings, packing support, liquid distributor, liquid
redistributor, mist eliminator, hold-down plate, etc.
(I) Suitable packing must he selected before the determination of tower diameter.
Packings can be divided in two broad classes.
@ProcessEng

(i) Regular packings: Grids, structured packings, stacked rings, etc. are of these
type. Grids are used for high gas rates as they offer very low pressure drop. They
are used in cooling towers. Structured packings are widely used in chemical process
industries. They are made from corrugated sheets with some perforations or wire
mesh. They provide high surface area with high void fraction. HETP (Height
Equivalent to Theoretical Plate) of structured packing is generally less than 0.5 m.
 Introduction to Process Engineering and Design

200
50 mni
13 mm
150
38 mm

| 100 /
25 mrn

50
(a) C"eramic Rascl lig rinj. s

0 10 20 30 40 50 60 70 80 90

200
(b) Metal Haschi g rings
150
50 mm
| 100 -—' 38 mm
13 mm
50
25 mnr~~

0 10 20 30 40 50 60 70 80 90
200
(c)C>rami : Bed saddles
150

I 100
25 mm
38 mm
50
13 mm

0 10 20 30 40 50 60 70 80 90

200
(cl)lS/letal P all rinj. s
150 JU 111111
Process Engineering Channel

38 mm
I 100
13 mm

50 25 mri
" ^

0 10 20 30 40 50 60 70 80 90
% flood
@ProcessEng

Fig. 9.4 Correlation Parameter y/for Cornell's Method3

(Reproduced with the Permission of McGraw-Hill Education. USA)

They are produced by many manufacturers. They are preferred for difficult distil-
lation operations, for high vacuum distillation, for high efficiency absorption
with low allowable pressure drop and also for increasing the capacity of existing
 Process Design of Absorbers

I—r-i-M t

rrlvt'fM
i-i—i-i
E 0.1 i >■ 25 mm
50 ram
0.05
3 mm

x
38 mm

0.01
0.1356 1.356 13.56 135.60

(a) Ceramic Raschig Rings

1 J—+

0.1 r-rrrt

0.05 13 mm
5 mm
! :
38 mm

0.01
0.1356 1.356 13.56 135.60
L
(b) Ceramic Bed Saddles

+—-1—
Process Engineering Channel

38 mm
S 0.1 ■1 !
tun
© 50 mm
0.05

13 mm
@ProcessEng

0.01
0.1356 1.356 13.56 135.60
L
(c) Metallic Raschig Rings
 Introduction to Process Engineering and Design

......
.......

38 mm
0.1 —i- 33 5 mm
50 mir r n
0
0.05 -f-t
13 mm

01
0.1356 1.356 13.56 135.60

(d) Metal Pall Rings

L = Liquid Rate, kg/(m • s2)

Fig. 9.5 Correlation Parameter for Various Packings3

(Reproduced with the Permission of McGraw-Hill Education, USA)

1.0
U >
k
I—
■4o
o—•
\
u-i
c \\

(J \
o
fa
o
o 0.5
1° \
-3
c
_o
Process Engineering Channel

0 50 100
Per cent flood

Fig. 9.6 Flooding Correction Factor, C3

(Reproduced with the Permission of McGraw-Hill Education, USA)

distillation column. Necessary data, correlations or graphs for calculating tower

@ProcessEng

diameter can be obtained from the manufacturer.

(ii) Random Packings:
Various types of random packings are used with packed towers. Most commonly
used are Pall rings, Berl saddles, Intalox saddles, Raschig rings, Tellerettes, Hy-
Pac, etc. Design data of these packings are given Table 9.2.
 Process Design of Absorbers

(a) Raschig ring (b) Berl saddle (c) Intalox saddle (metal)

(d) Intalox saddle (ceramic) (e) Tellerette (f) Pall ring

Fig. 9.7 Random Packings

Pall rings are the preferred and commonly used random packings but their
cost per unit volume is high. Pall rings require minimum diameter and minimum
height for the given absorption or distillation duty as compared to other types of
random packings. Pall rings are available in metals and plastics. For high
temperature services polyethylene or polypropylene Pall rings cannot be used.
Plastic packings are also attacked by some organic solvents. For corrosive serv-
ices ceramic Berl saddles are cheaper than metallic Pall rings. For example in
distillation of the mixture of phosphorous trichloride and phosphorous oxychlo-
ride, packed tower with ceramic packing is used. Ceramics are brittle at high
temperature and have poor strength. For very high temperature and corrosive
services glass packed columns with glass Raschig rings are preferred against
packed column of special alloy. For example, in vacuum distillation (for extractive
distillation) of concentrated nitric acid using concentrated sulfuric acid as solvent,
it is carried out in glass packed tower with glass Raschig rings. Raschig rings are
the cheapest packing material but are less efficient. Raschig rings require the
maximum diameter and height for the given absorption or distillation duty
Process Engineering Channel

compared to other types of random packings. Hence, total fixed cost of packed
column is higher. Diameter of tower is recommended to be more than 10 times
the packing size.
(//) Liquid distributors:
Various types of liquid distributors, used with packed tower, are shown in
Fig. 9.8. Uniform initial distribution of liquid at the top of packed bed is essential
for the efficient mass transfer operation.
@ProcessEng

For small diameter packed columns (having diameter less than 0.3 m) single
point distributor like one spray nozzle is adequate. For large diameter packed
columns, mulli point distributors like perforated pipe distributor, trough type dis-
tributor, orifice distributor, etc. are used. As per the Perry's Handbook3, for each
194 cm cross sectional area one distribution point is required. As per the Eckert's
 1 586 Introduction to Process Engineering and Design

Trough type distributor Weir riser distributor

Holes

Perforated pipe distributor Orifice type distributor

Fig. 9.8 Different Types of Liquid Distributors

recommendations, number of streams or number of distribution points required

in packed tower are given as follows:

Table 9.4 Number of Distribution Points in Packed Tower3

Column diameter, m No. of points/m2

0.4 340
0.75 170
> 1.2 40

Perforated pipe distributors are preferred for column diameter ranging from
0.3 m to 1 m. It is used with clean liquids and offers minimum restriction to gas
flow. They are preferred with reasonably constant flow rate.
Trough type distributors are preferred for columns having diameter greater
than or equal to 1.2 m. It can be used with liquids having solid in suspension.
Process Engineering Channel

Trough type distributors are fabricated from metal sheets, plastics or ceramics.
This distributor consists of a series of troughs containing side notches. It provides
good liquid distribution with a large free area for gas flow.
Orifice type liquid distributor is also preferred for large diameter packed
column. This type of distributor consists of flat perforated tray equipped with a
number of risers or short stand pipes. Ideally gas rises upward through risers or
@ProcessEng

short stand pipes, while liquid maintain the certain level over the perforated plate
and flows down through perforations. The risers should be sized to give suffi-
cient area for gas flow without creating a significant pressure drop. The holes
(perforations) should be small enough to ensure that there is a level of liquid on
the plate at the lowest liquid rate but large enough to prevent the distributor over-
flowing at the highest rate.
 Process Design of Absorbers

In weir type distributor gas and liquid (both) are flowing through the same
stand pipes. Notched weirs are provided in upper portion of stand pipes. Certain
level of liquid is maintained over the tray and liquid flows over notched weirs
and falling down through the same pipes from which gas rises upward. Weir type
distributor is preferred with fluctuating liquid flow rates.
(Ill) Liquid redistributor:
After travelling a certain distance in a packed tower, considerable fraction of
liquid is migrated to the column wall and flows down in the vicinity of column
wall while the gas rises upwards through the central portion. This phenomena is
called channelling. Liquid redistributor collects the liquid that has migrated to
the column wall and redistributes it evenly over the next bed of the packing.
For small diameter coloumn (D < 0.6 m) wall wiper type liquid redistributor is
preferred. It collects liquid from the column wall and redistributes it into the
central portion. Sometimes packing support plate itself acts as liquid redistributor.
Different types of liquid redistributors are shown in Fig. 9.9.

Shell
Straight
side wiper

Cone side
wiper
Pyramid support
and redistributor
VapoUr
Liquid

(a) (b)
(a) Wiper redistributors (b) Bell-cap redistributor

Fig. 9.9 Different Types of Liquid Redistributors

(IV) Packing support:

The function of packing support is to carry the load of wet packing bed without
Process Engineering Channel

providing excessive restriction to gas and liquid flows. It also acts as distributor
for both streams. Poor design of packing support provides higher pressure drop
and can cause premature local flooding. Two types of packing supports are used.
(Fig. 9.10)
(i) Countercurrent type: Example; Mesh type packing support
(ii) Separate flow or gas injection type: Example; Cap type packing support,
beam type gas injection support, etc.
@ProcessEng

In counter current type packing support liquid and gas both are flowing through
the same openings in counter current direction. Major open area of counter cur-
rent type packing support is occluded by packing pieces resting on it. Hence, this
type of packing support provides the low value of net free area (50% or less).
Column diameter is decided based on the characteristics of packing material.
Bed saddles, Raschig rings, etc. provide the lesser free area for flow of gas,
 Introduction to Process Engineering and Design

Welded ring support Wire mesh support

(a) Counter current type packing support

Gas
) o

o Gas
o
o
o

o l"' risers
O OoO
0
o o o O /

Liquid Liquid
downflow

Beam type Support plate, Cap type

(b) Separate flow or gas injection type packing support

Fig. 9.10

hence with such packings, counter current type packing support can be used. But
other packings like Pall rings, structured packings, etc. provide higher % free
area for the flow of gas (85% or more). Hence, with these type of packings,
counter flow type packing support cannot be used. Gas injection type packing
support can be designed for free area up to 90% and because of their geometry
there will have very little occlusion by the packing. In this type of packing sup-
port separate flow passages or openings are provided for gas and liquid streams.
Gas inlets are provided above the liquid level. With packing materials like Pall
rings, structured packings, etc. gas injection type packing support is recommended.
Process Engineering Channel

(V) Hold-down Plate:

Hold-down plate is required to prevent damage to the packing which can re-
sult due to a breakdown in normal operating conditions. At high gas or vapour
flow rates, packing at the top can be fluidized. This may result in breaking or
deshaping of packing. Ceramic packings can be easily broken which may settle
in voids of the packed bed and plug the flow channels. In case of metal packings,
@ProcessEng

deshaping may take place and the deshaped pieces can plug the flow channels. In
case of plastic packings, they may fly away with gas or vapour and seat at various
locations in the column. Also plastic packing may break and seat randomly in the
tower.
Hold down plate, generally in the grid form or the screen form, can be used to
prevent such fluidization. While heavier hold down plates are used for ceramic
 Process Design of Absorbers

and metal packings, lighter hold down plates of similar construction are used for
packed towers with plastic packing. Hold down grids/screens have generally poor
open area (< 50% of internal cross-section of the tower). However, size of opening
in the grid/plate are fixed in such a manner that fly off of the packing material can
be prevented.

Example 9.1
Design a scrubber for absorbing acetone vapour from air-acetone vapour mixture by
using pure water as solvent. The temperature in the scrubber is 250C and scrubbing is
isothermal. Operating pressure of scrubber is near atmospheric. A mixture of air with
acetone vapour containing 6% by volume of acetone is passed through the scrubber.
This mixture contains 1400 nrVh of air. The scrubber is required to absorb 98% of the
acetone.
Solution:
Refer Fig. 9.1.
Let Gs = Molar flow rate of air, kmol/h.
G[ = Molar flow rate of incoming air-vapour mixture, kmol/h
y, = Mole fraction of solute (vapour) in incoming air-vapour mixture

yi kmol of vapour
1 — y| kmol of air

Gj = Molar flow rate of outgoing air-vapour mixture, kmol/h

y = Mole fraction of vapour in outgoing air-vapour mixture

y2 kmol of acetone
Y
2 =
1 - y2 kmol of air

X2 = Mole fraction of solute in incoming solvent = 0

X2 kmol of acetone
X2 = —— = 0
I - X2 kmol of water

L2 = Ls - Molar flow rate of solvent at top, entering the scrubber, kmol/h

L, = Molar flow rate of solution leaving the scrubber, kmol/h
X\ = Mole fraction of acetone in liquid solution leaving the absorber
Process Engineering Channel

x, kmol of acetone
X, = —
1 - x, kmol of water
Flow rate of air Gs = 1400 m3/h at 1 atm and 25 0C

pM 1 x 29
Density of air pA =
RT 0.082 06 x (273 + 25)
@ProcessEng

pA = 1.1859 kg/m3

1400x1.1859
Gs = = 57.25 kmol/h
29
 590 Introduction to Process Engineering and Design

= 0.06 (mole % = volume %)

r, = = 0.063 83 tool of acetone

1 - >-| kmol of air

Scrubber is required to absorb 98% of acetone.

kmo1 ()facetone
^ = 0.02 xj, = 0.0012, Y-, = —1— = 0.001 201 44
1-^ kmol of air

X2=0, Ls = ?
Ls: To find the value of Ls, first the minimum amount of solvent required Lsm for the
desired separation is to be determined.
Phase equilibrium equation

Pv
y - mx — —x
P,
At 250C. vapour pressure of acetone4

.In p., = 16.6513 2940.46 (Antoine equation),

T - 34.93

where, pv = Vapour pressure of acetone at 25 0C, torr

T = Temperature, K

iIn p = 16.6513 - 2940.46

v
(273+ 25)-35.93
pv = 228.416 torr

228.416
m = = 0.3
760

3' = 0.3x and —— = 0.3- *

l+T 1+X

Table 9.5 Equilibrium Data Calculations

Process Engineering Channel

y x
y r= x= — x=
l-y m I -A-

0 0 0 0
0.0012 0.001 2014 0.004 0.004 016
0.01 0.0101 0.033 0.034 12
0.02 0.0204 0.067 0.0718
0.03 0.0309 0.1 0.111
@ProcessEng

0.04 0.041 67 0.133 0.1534

0.05 0.052 63 0.167 0.2
0.06 0.063 83 0.2 0.25
 Process Design of Absorbers 591

0.07

y, = 0.063 83
0.06 //

//

0.05

0.04 /,

0.03 /
/
/

0.02 /
/

0.01 /
/
j f

72 = 0.0012
0 f 0-05 0.1 0.15 0.2 0.25 0.30
^1 = 0.0184 ^l, 0.2304
X
Fig. 9.1 I Determination of Minimum Amount of Solvent

Solute balance at minimum solvent rate

G
s(yi-y2) = Lsm(Xlm-X2)
57.22 (0.063 83 - 0.001201 44) = Lsm(Xlm - 0)
where Lsm = Minimum amount of solvent required, kmol/h
Process Engineering Channel

Xlm = Value of X, corresponding to the minimum amount of solvent

Value of Xlm can be obtained from the graph. Here, the curve of 7 vs X (equilibrium
curve; Fig. 9.11) is concave downward, hence the tangent is drawn from (X2, Fj) point
and is allowed to intersect the horizontal line at 7,.
Intersection point is (Xlm ,7,)
Xlm =0.2304 (from Fig. 9.11)
@ProcessEng

57.22 (0.063 83 - 0.001 201 44) = Lsm(0.2304 - 0)

Lsm = 15.55 kmol/h
Actual amount of solvent should be the greatest of the following values.
(i) Ls = 1.5 Lsm = 23.33 kmol/h L2 = 23.33 x 18 = 419.94 kg/h
 Introduction to Process Engineering and Design

1x1000 .
(ii) Ls = ——— = 55.55 kmol/h, i.e. about 1 nr/h (minimum flow rate required to

faeiltate the use of a centrifugal pump)

(iii) Ls = Minimum wetting rate required to form a liquid film over all the packing. But
minimum wetting rate required can be calculated after finding the tower diameter.
Tower diameter can be determined after deciding the actual amount of solvent.
Hence, it requires trial and error calculations.
For the first trial let L, = 55.55 kmol/h = 1000 kg/h
Tower diameter required at top

F,r
Li, = (9.15)
G P/.
, =™
L , • off v
Mass velocity •,!,kg/(irr
liquid /<- 2 • s)\ = 1000/3600
w
{k/4) D'

Lw = 0.2778/^D2

Gm = Mass velocity of gas, kg/(m2 • s)

Molar flow rate for gas - vapour mixture at the top
G2 = Gs (1 + y2) = 57.25 (1 + 0.001 201 44 ) = 57.3189 kmol/h
Average molar mass of gas - vapour mixture at the top
Mav=I.(Miyl)
Mav = 0.012 xM of acetone + 0.9988 x M of air
Mav = 0.0012 x 58 + 0.9988 x 29
Mav. = 29.0348 kg/kmol

(57.3189 x 29.0348 )/3600 o 462

1
Gw = r = kg/(m • s)
(k/4) D~ (K/4)D-

Density of vapour gas mixture at top

pM 1x29.0348 ,
pc, = —= = 1.187 kg/m3
RT 0.082 057 x( 273+ 25)

Pc 0.2778 U87=a02072
F -
Flg -
Gm, ^ pL 0.462 V 1000
Process Engineering Channel

From Fig. 9.3, KF = 0.2

Let actual veocity of gas = 66% of folding velocity

K
x 100 = 66%
Kp

A: = (0.66)ix 0.2 = 0.08712

@ProcessEng

For K = 0.087 12 and FLG = 0.020 72

Pressure drop/m of packing height = 75 mm H20/m of packing (From Fig. 9.3)
Mass velocity of gas through tower

K
PgPl 8
cv,.= (9.18)
2
rP ¥ Pl
 Process Design of Absorbers

Density of liquid ,
y/ = = \ , pL= 1000 kg/m3
Density of water

g = 9.81 in/s2
Viscosity of water at 20oC, /dL= [ cP = I 0"3 kg/(m ■ s)
Select 25 mm polypropylene Pall rings as packing.
Packing factor Fp= 170 m_1 (Ref. Table 9.2)

vl/2
f 0.08/12X1.!«/xiuooxy.81
a =
170x1 x l02

= 2.4428 kg/(m2 • s)

Mass flow rate of gas - vapour mixture

Tower area required at top =

(57.3189 x 29.0348)73600
= 0.1892 m2
2.4428
Tower diameter required at top = 0.49 m ~ 0.5 m

Tower diameter 35Q

= 14 > 10 (satisfactory)
Packing size 25

Liquid rate = = 5.09 m3/(m2 ■ h)

—(0.50)2
4
Hence, it is greater that 4 m3/(m2 ■ h) (minimum wetting rate required for polypropylene
surface)

Liquid rate = —— = 5093 kg/(h • m2)

^(0.50)2

It is less than 7340 kg/(h • m2), minimum wetting rate specified in literature (Ref. 2).
Based on Morris and Jackson's equation, minimum solvent required
Lmin = MWR ■ a, (9.5c)
Process Engineering Channel

For 25 mm polypropylene poll rings ar= 205 m2/m3 (From Table 9.2)
For 25 mm polypropylene Pall rings MWR = 0.08
Lsm = 0.08 x 205 = 16.4 m3/(m2 • h)
Considering the last method for predicting minimum wetting rate, let Ls = 3500 kg/h
= 194.4 kmol/h

a..
Attop r- = 3500/3600 xj 1.187 =0.0725
F
@ProcessEng

ir
0.462 V 1000
From Fig. 9.3, A:F = 0.17
Let actual velocity = 66% of flooding velocity
/i: = (0.66)2x 0.17 = 0.074
Pressure drop = 66 mm ^O/m of packing
 Introduction to Process Engineering and Design

Mass velocity of gas through tower

\l/2 /
K
Pc Pi. S 0.074 x 1.187 x 1000 x 9.81 nI/2
G =
F,, V 170x I x l02

= 2.2514 kg/(m2 • s)

0.462
Tower area required at top. A, =
2.2514

A, = 0.2052 m2=

D = 0.511 m = 0.52 m

3500
Liquid rate = = 16 480.54 kg/(m • h) = 16.48 m7(nr • h)
2
—(0.52)
4
Hence it satisfies the conditions.
Tower diameter required at the bottom:
Average molar mass of gas-vapour mixture
Mw = ZMiyi = y, x 58 + (/ -y,) x 29 = 0.06 x 58 + (1 - 0.06) x 29
Mav = 30.74 kg/mol
density of gas-vapour mixture at bottom

PAT I x 30.74
Pc, = = 1.257 kg/m3
RT 0.082 057 x( 273+ 25)
For Ls = 3500 kg/h = 194.44 kmol/h
Acetone balance
Gs{Y[-Y2) = Ls(Xx-X2)
57.25(0.063 83 - 0.001 201 44) = 194.44(A:I - 0)
X, =0.018 44

X,
x, = = 0.0181
l + X,
,3
Density of water = 1000 kg/nr
Process Engineering Channel

Density of acetone = 790 kg/m3

Average density of liquid solution leaving the scrubber

1
PL =
I(VF,-/p,)
W, =xlx58/[x1x58 + (l-xl)x 18]
@ProcessEng

0.0181x58
= 0.056
0.0181x58 + 0.9819x18

1
Pl = = 985.33 kg/m3
0.056 + (1-0056)
790 1000
 Process Design of Absorbers

L, =4(1 +X,) = 194.44(1 +0.018 44) = 198.025 kmol/h

Average molar mass of liquid solution
Mav = 0.0181 x 58 + 0.9819 x 18 = 18.724

(198.025 xl8.724)/3600 j 03 ,
L
\ = ; = 7- kg/(m- • s)
{KIA)D {tzIA) D

G, = Gs(l + Y]) = 57.25(1 + 0.063 83) = 60.904 kmol/h

(60.904x30.74)/3600 Q 52 ,
G
i = —T3 = —T—T kg/(m- • s)
(K/A) D' iK/A)D'

Pg1 1.03 I 1.257

At bottom, Flg = x (9.15)
a p, 0.52 985.33

fLG = 0.0707
4-= 0.175 (From Fig. 9.3)
Let actual velocity of gas = 66% of flooding velocity
K = (0.66)2 x 0.175 = 0.076 23
A/? of packing = 66 mm of FLO/m of packing
mass velocity of gas through tower

/ „ \l/2 1/2
^ Pc, Pz., g 0.076 23 x 1.257 x985.33 x 9.81
G, =
rPVM0L2 170 xf 1000 1 xl02
V 985.33 y /
= 2.316 kg/(m- • s)

0 52
- = 0.2245 m2
2.316

A = — D2 = 0.2245 m2
4
D = 0.5346 m
Thus the diameter of the entire tower, D = 0.54 m
Process Engineering Channel

Nog-. (Number of overall gas phase transfer units)

To calculate the NOG, draw the operating line on the graph which starts from (X2, T,)
and terminates at (X,, T,), i.e. starts from (0,0.00 120 144) and terminates at (0.018 43,
0.06 383). (Ref. Fig. 9.11)
Given system is a dilute system (x, < 0.1). Here the portion of equilibrium curve
under the operating line can be approximated as straight line. Hence, in the given case
Nog can be calculate by the following equation.
@ProcessEng

J m Gn m G,.
-In I- Zl + ■ (9.12)
Nqg -
mG m /
n
L..,
 Introduction to Process Engineering and Design

G, + G2 60.904+ 57.3189)
—D2
m G
n
= 0.3 x = 0.3x
Li + Ln ' 198.025 +194.45 N
fD2

= 0.090 38

1 0.06
^OG - -In (1-0.090 38) x 0.090 38
1 - 0.090 38 0.0012

= 4.1988
Here, acetone is highly soluble in water. Hence liquid film resistance is negligible as
compared to the gas film resistance. Hence, height of packing in the given case should
be determined by equation;

^ - Nqg " HQG (9.7)

HoG: Height of Overall Gas Phase Transfer Unit

Hqg - + m H, (9.19)
L.,

Based on Onda, Takeuchi and Okumoto's method.

Height of gas phase transfer unit

G
h
g = (9.21)
Kg ae P Mg

G = Superficial mass velocity of gas, kg/(m2 • s)

(0.462+ 0.52)/2
= 2.1439 kg/(m ■ s)
2
—(0.540)
4
Effective area of mass transfer ae is determined by following equation.

0.5
a„ o
0.392
a3 (9.23)
a. = Wc%R««)
Process Engineering Channel

a, = 205 nf/nf
Surface tension data for acetone at the scrubbring temperature can be calculated by a
group-contribution method, given in Ref. 3.

mN dyn
<7l = Liquid surface tension in or
m cm

XI+XJ 0.0181 + 0 ,
@ProcessEng

X,. = r „ = = = 9.05 x 10-3 = 0.0095

O
[^] for Acetone:
 Process Design of Absorbers

[^] = 55.5 x 2 + (9 + 22.3) = 141.7

(From Table 3.343 of Ref. 3)
Surface tension of Acetone
(j1/4 = [^]( pL - pG) (Ref. Eq. 3.151 of Ref. 3)
where, pL, pG are in mol/cm3

-3
1/4
(790-2.372) x 10
cr = 141.7
58

I x 58 ..
Density of pure acetone vapour, pr, = = 2.372 kg/m
0
0.082057 x( 273+ 25)
l/4
a = 1.9242
d = 13.71 dyn/cm
Actual surface tension data are reported by Timmermans (Ref. 5)
cr = 24.5 dyn/cm at 250C
Thus it can be seen that group-contribution method may give erronous results. It is advised
to use the actual value as far as possible.
For pure water, o = 10 dyn/cm
aL = S((7^-) = 24.5 x 0.009 05 + (1 - 0.009 05)70
<jl = 69.58 dyn/cm or m N/m
For dilute aqueous solution, surface tension of water may be taken for calculations.

CaL = Liquid capillary number = (9.24)

Pl°l
xav = 0.009 05
Wav = (0.009 05 x 58)/(0.009 05 x 58 + (1 - 0.009 05) x 18)
Wav = 0.028 58 (average mass fraction)
1 1
p.L = = = 992.46 kg/m3
Z(w(/p() 0.02858 (1-0.028 58)
790 1000
gl = 69.58 x 10-3 N/m

(3500/3600 + 1.03 )/2

Lw = = 4.3712 kg/(m • s)
(^/4)(0.54)4
Process Engineering Channel

pL = Viscosity of liquid mixture in kg/(m • s)

In = I(w/ In p() (Eq. 3.107 of Ref. 3)
Viscosity of acetone at 250C = 0.33 x 10"3 kg/(m • s)
Viscosity of water pH, = 0.95 cP = 0.95 x KT3 kg/(m • s)
In pL = 0.028 58 In (0.33 x lO"3) + (1 - 0.028 58) In (0.95 x lO"3)
pL = 9.211 x lO-4 kg/(m • s)
@ProcessEng

9.217 xl0"4x4.3712
C,„ =
'"L~ 992.46 x 69.58 x l0"3
= 5.834 x 10,-5
 Introduction to Process Engineering and Design

6 G,w
Reynolds number, ReG =

Gw = 2.1439 kg/(m2 ■ s), a, = 205 m2/m3

Viscosity of gas mixture

_ ^ O'VAk)
(9.32)
G
^ ~ hiyjbj)

y, +y2 0.06 + 0.0012

Vav = = 0.0306
2 2
2
[l + (^/^),/2(M7./M,.)l/4]
<S>ii = (9.33)
1/2
[8(1 + M,./M,.)]

N
(Mi
and <t>ji =
I A- . \ MjJ J

Note that here 0 is only a parameter (and does not represent heat load)
Viscosity of acetone, luac = 750 x 10~7 P = 750 x 10"5 cP
Viscosity of = 1850 x 10^7 P = 1850 x 10"5 cP
2
750 r f 29 y
1+
1850 J 158 J
<t>il = = 0.4812
1/2
[8(1 + 58/29)]

1850 Y 58
x 0.4812 = 2.374 (Here i = acetone, j = air)
750 A 29

0.0306 x 750 x 10"5 + (1 - 0.0306) x 1850 x 10 -5

Vg =
(1 - 0.0306) x 0.4812 + 0.0306 x 2.374

= 0.033 69 cP = 0.033 69 x lO"3 kg/(m • s)

Process Engineering Channel

6G 6x2.1439
Rec = = 1862
-3
atVc 205x0.033 69x10

Z = /Voc • Hqg = 4.1988 HOG

— = 0.31——(C L ReG f 392 (9.23)

a. 7oa
@ProcessEng

69.580'5
= 0.31 (5.834 x 10-5 x 1862)\().392
205 z0'4

= 1.0832
-7 0.4

For the first trial calculations, let H0G = 0.6 m

 Process Design of Absorbers

Approximate values of HOG for random packings of size 25 mm is 0.3 to 0.6 m, for 38
mm size it is 0.5 to 0.75 m and for 50 mm size it is 0.6 to 1.0 m (Ref. 2).
Z = 4.1988x0.6 = 2.52 m

a„ 1.0832
= 0.748 42
205 2.52 0.4
ae = 153.43 m2/m3 of packing
Gas phase transfer coefficient Kc is determined by following equation.
0.7 / \ 1/3
kgrt Gw ) Pg -2 (9.26)
= C, {a, dp)
atDc v ai PG , , Pg DG ,
where. /? = 8314 J/(kmol • K)
T = operating temperature = 273 + 25 = 298 K

P
Pg = , M.w = I.yiMi = 0.0306 x 58 + (1 - 0.0306) x 29 = 29.8874
RT

1x29.8874
= 1.2222 kg/m3
0.082 057 x 298
Dg = Gas phase diffusion coefficient, nr/s
From Table 3.318, of Ref. 3,
At 250C diffusivity of acetone in air
Dg =0.109 cm2/s = 0.109 x lO-4 m2/s
D oc yl.75
g

\l.75
4 298
Dg = 0.109 x l(r x = 1.2706 x KT5 m2/s
273
C, = 5.23 for d,, > 12 mm

8314x298 0.7
2.1439
^G-X = 5.23
-3
205x1.2706x10,-5 205x0.033 69x10

-3 ,1/3
0.03369x10
X x (205 x 0.025).-2
Process Engineering Channel

-5
1.2222x1.2706x10

Kgx9.5U 82 x 108 = 5.23 x 55.509 x 1.2945 x0.038 07.

Kg = 1.504 x 10-8 kmol/(m2 • s ■ Pa)
Height of gas phase transfer unit

G..,
HG = (9.21)
@ProcessEng

Kg ae p Mg

Gw = Average superficial mass velocity of gas, kg/(m2 • s)

Gw = 2.1435 kg/(m2 • s)
Kg = 1.504 x 10~8 kmol/(m2 • s ■ Pa)
a., = 153.43 m2/m3
 Introduction to Process Engineering and Design

p = operating pressure = 101.325 x 103 Pa

M = average molar mass of gas = 29.8874 kg/mol

2.1439
HG =
1.504 x I0" x 153.43 x 101.325 x 103 x 29.8874
8

= 0.3068 m
Height of liquid phase transfer unit

HL = —^ (9.22)
KLaepL
Lw = Average mass velocity of liquid through tower

[(3500/3600)+ 1.03]/2 8.7425

= 4.3712 kg/(m2-s)
7r/4(0.54y

ae = 153.41 m2/m3, p, = 992.46 kg/m^

4.3712 2.871 xlO-5

Hl =
x 153.41 x 992.46 KL
Liquid phase mass transfer coefficient KL can be determined by the following equation

1/3 2/3 / \ -0.5

r Av '
Klx i PL
^ = 0.0051 (a,*,)04 (9.27)
D
yPL L ,
pL = 992.46 kg/m3, ^ = 9.217 x lO"4 kg/(m ■ s)
Lw = 4.3712 kg/(m2 ■ s), g = 9.81 m/s2, ar = 205 m2/m3
dp = 0.025 m
aw = wetted surface of packing, m2/m3

\O.75
OV
= 1 - exp -1.45 ReV (9.28)
a,
3
For polypropylene packing, gc = 33 x 10 N/m (Table 9.3)
3
a, = 69.58 x lO" N/m

L 4.3712
Process Engineering Channel

Liquid Reynolds number, ReL =

-4
a,PL 205x9.217x10
= 23.134
2.. // ppg)
Froude number of liquid, FrL = L^aji „2,

4.3712 x 205
= 4.0538 x lO"4
2
992.46 x 9.81
@ProcessEng

Weber number for liquid.

4.37122
WeL= L-,/(pLGLa,) = = 1.35 x lO"3
3
992.46 x 69.58 x 10" x 205
 Process Design of Absorbers

0.75
" IV . 33
— = 1 - exp -1.45 x 23.134 o.i
a. 69.58

x (4.0538 x 10"4 )"005 x (1.35 x 10"3 )a2

a.
= 1 - exp (-0.4472)
a,

a.
= 0.3606
a,
aw = 0.3606 x 205 = 73.923 m2/m3
Dl = Diffusivity of acetone in water, m2/s

Dl can be determined by Wilke and Chang equation

(117.3xlO-|8)(0Ms)a5r
Dl =
HV 0.6

(Equation 2.44, of Ref. 1)

where, VA = Molar volume of solute at normal boiling point, m3/kmol
0 = Association factor for solvent = 2.26 for water (a parameter)
Ms = Molar mass of solvent = 18 kg/kmol
/u = Solution viscosity, kg/(m ■ s ) = 9.217 x 10'4 kg/(m • s)
T = Temperature, K = 273 + 25 = 298 K
For calculating VA, a group contribution method, given in Treybal is recommended.
From Table 2.3 of Ref. 1

Table 9.6 Group Contributions for Acetone1

Atom Volume, m Vkmol Total No. of atoms

C 0.0148 3
H 0.0037 6
O 0.0074 1
Process Engineering Channel

= 0.0148 x 3 + 0.0037 x 6 + 0.0074 x 1 = 0.074 mVkmol

0.5
(117.3 x 10"18) x (2.26 x IS)1'3 x 298
DL = = 1.154 x 10-9 m2/s
4 06
9.217 x lO" x(0.074) -

1/3 >2/3
992.46 4.3712
K, = 0.0051 -
-4
@ProcessEng

9.217 xl0"4x9.81 ^73.923 x 9.217 x 10

-4 \-0.5
9.217 X10
X x (205 x 0.025) 0.4
-9
992.46x1.154x10
 Introduction to Process Engineering and Design

Kl x 47.88 = 0.0051 x 16.02 x 0.03525 x 1.9225

= 1.1564 x lO^kmol/lm2 • s ■ Pa)

2.871 xl 0"5
Hl =
1.1564 xl 0-4
HL = 0.248 m

Hog=Hg+ m^-HL (9.19)

m
Hog = 0.3068 + 0.09038 x 0.248 = 0.329 m
Z = Nog ■ Hog = 4.1988 x 0.329 = 1.38 m
For second trial calculations, let Z = 1.4 m

1.0832 x 205
= 194 m2/m3
04
1.4 "

Hri = 0.3068 x = 0.2426 m

194

153 43
and H, = 0.248 x - = 0.196 m
194
Hog = 0.2426 + 0.090 38 x 0.196 = 0.2603 m
Z = 4.1988 x 0.2603 = 1.093 m < 1.382 m
Hog for 25 mm size random packing ranges from 0.3 to 0.6 m.
Let Hog = 0.3 m
Z = 0.3 x 4.1986 = 1.26 m = 1.3 m
This is the value of packed bed height based on Onda, Takeuchi and Okumoto's method.
Cornell's method:
For Pall rings, height of gas phase transfer unit

0.017 y/ o124 Z033 5c"-5

Hg = — (9.29)
06
(^/z/s) '
y/ = Correlation parameter = 60 m for metal Pall rings (Fig. 9.4)
For polypropylene Pall rings, data for i//are not available. Hence, assume that the value
Process Engineering Channel

of i// for polypropylene Pall rings and y/ for metal Pall rings is same.
For PP Pall rings y/=60m
D = 0.54 m, z = 1.3 m (Assume for the 1st trial calculations)

=
Mc 0.03369 xl 0"3
Sc'r.
G Pc Dc 1.2222 X 1.2706 x 10~5

= 2.1695
@ProcessEng

,0.16
Pl_ 3
fi = with \iw= 10 Pa • s
V Pw J
_4 xO.I6
9.217x10
= 0.987
io-3
 Process Design of Absorbers

,1.25
Ph_
f2 = with pw = 1000 kg/m3
Pl

1.25
1000
= 1.01
992.46

o.
o,,
h - where a,,, = 72.8 mN/m
o.

0.8
72.8
= 1.038
69.49
L = Liquid phase mass velocity = 4.3712 kg/(m2 ■ s)

0.017 x 60 x 0.54124 x 1.3033 x 2.1695a5

^G = = 0.3085 r
0.6
(4.3712x0.987x1.01x1.038)

Height of liquid phase transfer unit.

,0.5 0.15
pC Pl
Hl =
3.28 PL DI 3.05

From Fig. 9.5, for L = 4.3712 kg/(m2 • s),

Correlation parameter (p for metal Pall rings = 0.05 m
Assume that <p for PP Pall rings is (p for SS Pall ring
(p = 0.05 m
C = 0.75 for 66% Flooding (From Fig. 9.6)

-4 0.5 0.15
0.05 x 0.75 9.217x10 1.3
hl = X
3.28 -9 3.05
992.46x1.154x10

= 0.2854 m

Gm
Hog =Hg+ m—HL = 0.3085 + 0.09038 x 0.2854
Process Engineering Channel

= 0.334 m
Height of packed bed, Z = Noc ■ H0G
Z = 4.1988 x 0.334 m= 1.4 m
For second trial calculations, let Z = 1.4 m
,0.33
1.4
Hg = 0.3058 x = 0.3134 m
1.3
@ProcessEng

0.15
L4
Hl = 0.2854 x = 0.2856 m
1.3
Hoc = 0.3134 + 0.090 38 x 0.2856 = 0.3392 m
Z = 4.1988x0.3392= 1.424 m
 Introduction to Process Engineering and Design

Let height of packed bed Z = 1.5 m (Higher than the values of Z obtained based on
Cornell's method as well as based on Onda, Takeuchi and Okumoto's method.)
No. of packing sections required = one
Liquid distributor: For clean liquid solvent and for small diameter tower perforated
pipe type distributor is satisfactory. It is recommended that one liquid stream must be
provided for each 194 cm2 area. (Ref. 3)
No. of holes (distribution points) required in pipe type distributor,

Cross sectional area of tower, cm2

nh =
194

(;r/4)(0.54)2 xlO4
= 11.8= 12

Let the velocity of water through the pipe = 2 m/s

Flow rate of water (solvent) = 3500 kg/h

Voumetric flow rate of solvent = x —^— = 9.7222 x 10-4 m3/s

1000 3600

d = 25 mm
Let the velocity of solvent through holes = 3 m/s
Let d,, = diameter of hole, m

9.7222 x lO-4
3
d,, —
= U.UUU
0.006 m
III = 6
U mm
llllll
Resulting pipe type liquid distributor is shown in Fig. 9.12.

Liquid

Q D
Process Engineering Channel

12 No. 6 0 holes

25 NB pipe
@ProcessEng

0 = 270

Fig. 9.12 Pipe Type Liquid Distributor

 Process Design of Absorbers 605

Packing support:
Packing support should be selected such that flow area provided by packing support for
the flow of gas should be greater than flow area (i.e. void) provided by packing material.
% Void space for 25 mm size polypropylene Pall rings = 90% (Ref. Table 9.2)
With Pall rings any gas-injection type packing support can be used.
Let type of packing support: Cap type packing support

0 = 54

0 90

34 No. 6 0 holes

0 10
5
4
t
170 210

Section XX
Fig. 9.13 Cap Type Packing Support

Actual outer diameter of packing support is greater than 540 mm as some portion of
packing support is sandwiched between two flanges.
Let h = height of slot in riser
x = width of slot in riser
d = diameter of riser
Process Engineering Channel

n = number of risers.
Dc = Inside diameter of column = 540 mm
If d = Dc/6, then nine number of risers can be provided on packing support.

540
= = nn
90 mm

Let, ns = number of slots per riser

@ProcessEng

Total area of slots of risers = n- n h x

Let x = 10 mm

7rd_=7rx90
n
s= = 14
2x 2x10
(If the distance between two successive slots is x mm)
 { 606 Introduction to Process Engineering and Design

Total area of slots of risers = 14x9x/?x 10x>0.9x — (540)2

Let diameter of weep hole = 6 mm, velocity of liquid through weep hole = 1 m/s

(9.722 xKT4)/!
2
No. of weeping holes requierd = =34
-(0.006 )2
4

9.4 PROCESS DESIGN OF SPRAY CHAMBER OR

SPRAY TOWER TYPE ABSORBER3 6

Spray absorbers are used for removing SCL (sulphur dioxide gas) form boiler
flue gases that is exhausted from a boiler. When very low pressure drop is essen-
tial and when incoming gas stream is contaminated by particulate matter, spray
absorbers are preferred over the packed tower type absorber. In the large scale
plant, boiler flue gases entering the absorber for the removal of SOjare available
at very low pressure (100 to 200 mm WC) and with very high volumetric flow
rate. These gases are also contaminated by particulate matters.
Spray chambers (absorbers) are having either circular or rectangular cross
section. Normally there is no packing in the spray absorber.
They are of two types.
(a) Vertical spray tower
(b) Horizontal spray chamber
Liquid phase residence time in spray absorbers is in the range of 1 to 10 s which
is very low. To compensate this, liquid phase resistance must be negligible. Hence,
a chemical reagent is added in the liquid phase to get the higher rate of absorption.

9.4.1 Process Design of Vertical Spray Tower3

In vertical spray tower gas stream is flowing vertically upward and liquid is sprayed
downward in various sections within the tower as well as from the sides by spray
nozzles.
Process design steps for vertical spray tower are as follows:
Process Engineering Channel

(i) Determination of tower diameter: Maximum permissible gas velocity through

vertical spray tower is 2.3 m/s. Actual velocity of gas through tower should be
less than 2.3 m/s to avoid the excessive entertainment of liquid droplets in the
exist gas. On fixing the actual velocity, tower diameter can be determined by
following equation.
@ProcessEng

(9.34)

where, D = Tower diameter, m

qv = Volumetric flow rate of gas, m3/s
m„ = Velocity of gas through tower, m/s < 2.3 m/s
o
 Process Design of Absorbers

(ii) Determine the number of gas phase transfer units required for the desired
separation by following equation

y, - yh
NG = ' (9.35)
^2
where, NG = Number of gas phase transfer units
ji = Gas phase solute mole fraction at inlet (at bottom)
^2 = Gas phase solute mole fraction at outlet (at top)
(iii) Calculate the total volume of spray section by following equation.

Ng x Gw
K= — — (9.36)
KGa

where, V = Volume of spray section, nr

Ng = Number of gas-phase mass transfer units
KGa = Overall volumetric gas phase mass transfer coefficient kmol/
[(s • m ) (mole fraction of solute in gas)l
Gm = Flow rate of gas phase, kmol/s
The best method for finding the KGa is from the similar type of commercial gas
absorption unit noting that same value of KGa can be used only with same value
of liquid flow rate to gas flow rate ratio.

9.4.2 Process Design of Horizontal Cross Flow Spray

Chamber6

For the given absorption duty total volume required by horizontal cross flow
chamber is considerably less than that of a vertical spray tower. Horizontal cham-
ber is having either rectangular or circular cross section. Gas passes horizontally
through it and liquid is sprayed vertically downward perpendicular to the direc-
tion of gas flow. Process design steps for horizontal cross flow chamber are as
follows.
(i) Determination of duct area or diameter:
Maximum permissible gas velocity through horizontal spray chamber is 7 m/s.
On fixing the actual gas velocity through horizontal chamber, duct area or diam-
Process Engineering Channel

eter can be determined.

(ii) Determine the number of gas phase transfer units, required for the desired
separation by following equation.
/ \
yvG = in ZL (9.37)
^2
@ProcessEng

where NG = number of gas phase transfer unit

yj = Gas phase solute mole fraction at inlet
y2 = Gas phase solute mole fraction at outlet
(iii) Total volume of spray section is determined by the same equation that is used
for vertical spray tower. (Eq. 9.36)
 608 Introduction to Process Engineering and Design

Example 9.2
Design the spray chamber for the following duty.
Volumetric flow rate of boiler flue gas = 24 000 SnrVh
Pressure of gas = 150 mm WC (gauge)
Temperature = 80 to 90 0C
SO2 concentration in boiler flue gas = 4000 ppm = 4000 x 10"6 kmol/kmol gas
Desired concentration of SO2 in the outgoing gas = 200 ppm = 200 x 10'6 kmol/kmol gas
Solvent = 1% lime solution
Solution:
Type of scrubber: Spray chamber
Position: Horizontal or vertical
(a) Tower diameter
(i) For vertical spray chamber:
Volumetric flow rate of gas = 24 000 Sm3/h
Volumetric flow rate of gas at actual operating condition

24000x10333 (273 + 90)

qv = x = 31 455.5 m3/h = 8.7376 m3/s
273 (10 333 + 150)
Maximum permissible gas velocity through vertical spray chamber = 2.3 m/s (to avoid
the excessive entrainment)
max = 2-3 m/s
Let actual velocity of gas through spray tower.
ug = 66% of Ug max
«„ = 0.66 x 2.3 = 1.518 m/s

^d2= —
4 ' ug
where D( = Inside diameter of spray tower

4 x qv 4x8.7376
D; = = 2.707 m
' y TTXUg ]] TT X 1.51 8

Let D( = 2.71 m = 2710 mm

(ii) Horizontal cross flow spray chamber;
Process Engineering Channel

Maximum permissible gas velocity through horizontal spray chamber = 7 m/s

max — 2 rn/s
Let actual velocity of gas through horizontal spray chamber, Ug = 66% of Ug max
Let cross sectional area of horizontal spray chamber, A= W2 for square duct
where, W = Width of chamber = Height of chamber

^=^ = M376
@ProcessEng

= 1 8913

11 „ 4.62

M/ =

W= 1.375 m
 Process Design of Absorbers 609

(b) Number of gas phase transfer units, N(1

(i) Number of gas phase transfer units required for desired separation, for vertical spray
tower

yi-yi
NG = (9.35)
yi

4000 x icr6 - 200 x icr6

= 19
200x10,-6
(ii) For horizontal spray chamber
/ \ ,-6
4000 x 10
NG = \n Zl = In =3 (9.37)
1-6
200x10
(c) Circulation rate of 1 % lime solution
(i) For vertical spray chamber:
To decide the circulation rate and height of gas phase transfer unit duplication of
similar/same type of commercial gas absorption unit is the best method.
From the existing vertical spray tower of one of the large scale industry, following
data are available.
Flow rate of boiler flue gas = 12 000 Sm3/h
Temperature of incoming gas = 80 to 90oC
SO2 concentration in inlet stream = 2500 to 4000 ppm
SOj concentration in outlet stream = Less than 400 ppm
Circulation rate of 1 % lime solution = 30 m3/h
Tower diameter = 1.7m
Height of spray zone = 3.5 m
Pressure drop = 100 mm WC (maximum)
Based on these data, circulation rate required for new tower
24 000 .
circulation rate = 30 x = 60 m /h
12 000
(ii) For Horizontal spray chamber
For the trial run, let the circulation rate of 1 % lime solution for horizontal spray chamber
= 60 m3/h
(d) Height of tower:
Process Engineering Channel

(i) Vertical spray tower:

Ng x Gm
V= (9.36)
Kg "
For existing tower

4000 x 10"6-400 xlO-6

NG = =9
@ProcessEng

-6
400x10

K
v= -(1.7r x 3.5 = 7.944 nF
4
12 000
Gm = = 535.38 kmol/h = 0.1487 kmol/s
22.414
 Introduction to Process Engineering and Design

9x0.1487 .
For existing tower, Kca = —^ — = 0.1685 kmol/(m- • s)

Volume of spray section required for new tower

24000 I
V= 19x x—!— /0.1685
K a
G 22.414 3600

= 33.54 m3 =
_ {K/A)
t -rr IA\ DfH
,-,2

where, H = Height of spray section required

33.54 m3 = (7r/4) x (2.7)2 x H
H = 5.86 m
Let H=6m
(ii) For horizontal spray chamber:
Mass transfer data are available for vertical spray tower only. Assume the overall volu-
metric mass transfer coefficient KGa for cross flow arrangement in horizontal spray
chamber to be 0.1 kmol/(m3 • s).
(less than the same for vertical position).

Nc x Gm 3 x 0.2974
V= — —= =8.922
Kca 0.1
V = 8.922 m3 = Vf 2L = (1.375)2 L
Length of spray section required with horizontal position, L = 4.72 m
Let L = 5 m
(e) Approximate pressure drop calculations:
(i) For vertical spray chamber
Pressure drop A/? oc G'-84^-84L (Ref. Eq. 5.5)
Pressure drop in actual vertical spray tower is 100 mm WC (maximum).
Pressure drop in proposed new vertical spray tower,
si.84 / _ 1 j^t.84

^oox^ftr^

A/? = 64.24 mm WC (within permissible limit)

(ii) For horizontal spray chamber
,-4.84
Process Engineering Channel

r24V-84 r 1.375
— x X —1
V 12 ) I 1.7 ) ,3.57
A/? = 1428 mm WC (very high)
To decrease the pressure drop, duct area must be increased. Let W = 2 m and L = 2.5 m

'2.5\
A/? = 100 x — x
— x —
v 12 7 IA.l) ^,3.5 J
@ProcessEng

= 116.45 mm WC (within permissible limit)

(Note: For this approximate calculation width or height of chamber W is considered as
diameter.)
 Process Design of Absorbers

Actually duct area (W2) is higher than circular cross sectional area ^ j anc
' hence

it will offer less pressure drop than the circular cross section.
Volume of spray section, V = (2)2 x 2.5 = 10 m3 (revised)
(f) Make-up of lime solution:
Lime required = Lime consumed in reaction + Drift loss.
Liquid particles entrained in the out going gas. Let drift loss = 0.2% of circulation rate
(based on experience in cooling tower).

Drift loss = — x 60 = 0.12 m3/h s 120 kg/h

100
Loss of lime as drift = 1.2 kg
Lime is consumed in reaction.
Ca(OH)2 + S02 -» CaS03 + H20

24 000
SOt consumed in reaction = x (4000 - 200) x 10 = 4.07 kmol/h
22.414
Ca(OH)2 consumed in reaction = 4.07 kmol/h = 4.07 x 74 = 301.18 kg/h

Lime required as CaCO, = (301.18 + 1.2) x ^ + 1.2 = 408.62 kg/h

Loss of water = Drift loss + Evaporation rate + Blow down = 1 % of circulation rate
CaC03 addition required = 408.62 kg/h
Water addition required = 6 m3/h = 6000 kg/h
Summary of results:
Vertical spray tower Horizontal spray chamber
1. Tower diameter = 2.71 m 1. Duct width and height = 2 m
2. Height of spray section = 6 m 2. Length of spray section = 2.5 m
3
3. Volume of spray section = 33.54 m 3. Volume of spray section = 10 m3
4. Pressure drop = 64 mm WC 4. Pressure drop = 116.45 mm WC
3
5. Circulation rate = 60 m /h 5. Circulation rate = 60 m3/h
6. Lime as CaCO, required = 408.62 kg/h 6. Lime as CaCC^ required = 408 kg/h
7. Makeup water required = 6 m3/h 7. Makeup water required = 6 m3/h
Comments: From the resulting data, it is clear that horizontal spray chamber is a
Process Engineering Channel

better option. But it is less common in operation as compared to vertical spray tower.
Here mass transfer data used for calculation are available for vertical spray tower.
Hence, design of the vertical spray tower is more reliable as compared to the horizon-
tal spray chamber.

9.5 VENTURI SCRUBBER3 7

@ProcessEng

Venturi scrubber is normally preferred for removing particulate matter from gas
stream as opposed to absorbing soluble vapour. Efficient contact between liquid
and gas is obtained in venturi scrubber. Gas is drawn into the throat of venturi by
a stream of absorbing liquid solvent sprayed into the convergent duct section.
Compared to spray absorber more efficient contact between gas and liquid is
 Introduction to Process Engineering and Design

provided by the venturi scrubber but at the expense of relatively large gas-side
pressure drop and a consequent higher power consumption. Spray absorber can-
not remove very fine particles (below 10 pm size) while the venturi scrubber can
remove the fine particles up to the size 2 pm effectively.
Venturi scrubber provides cocurrent contact (over all) between liquid and gas.
The fractional solute removal for a dilute system in venturi scrubber is given by
following equation.

yi~y2 t? (i - wA-2/3'2)
Fractional solute removal = —
yi f j + mGM
L
V M y

=
where, ^ Mcde fraction of solute in gas phase at outlet
^2 = Mole fraction of solute in gas phase at inlet
m = Slope of equilibrium curve
X2 = Mole fraction of solute in incoming solvent
Gm = Molar gas phase velocity, kmol / (nr ■ s)
Lm = Molar liquid phase velocity, kmol / (m2 • s)
rj = Mass transfer efficiency, calculated by following equation.

il=l- e-No (9.38)

where, NG = Number of overall gas-phase mass transfer units can be calcu-
lated by following equation.
NG = {KGaKYIp^ec (9.39)
where, KGa = Overall volumetric gas-phase mass-transfer coefficient for di-
lute systems, kmol/(s ■ m3)
R = Ideal gas constant = 8314 J/(kmol ■ K)
T = Operating temperature of gas ■ K
0C = Effective gas-liquid contact time, s
p, = Operating pressure, Pa
The number of transfer units, NG that can be achieved in venturi scrubber is in the
range of 1 to 2.
Process Engineering Channel

The liquid to gas ratio for venturi scrubber is in between 0.7 to 2.7 L/nr.
Throat velocity is kept in between 60 to 150 m/s. The estimated pressure drop
• 1
across the venturi scrubber is given by following equation (Hesketh equation ).

AP = 2.584 x lO"3 v2 pG 133

(L'/G')078 (9.40)

where, AP = Venturi pressure drop from inlet duct to the outlet duct, cm WC
@ProcessEng

vG = Gas velocity in the throat, m/s

pG = Gas density, kg/nr
Ath = Venturi throat area, cm"
L'/G' = Liquid to gas ratio, L/m3
 Process Design of Absorbers

Example 9.3
Predict the fractional solute removal and pressure drop in a venturi scrubber based on
the following data.
Volumetric flow rate of boiler flue gas = 24 000 NnrVh
Discharge pressure of gas from venturi = Atmospheric
Temperature of gas = 80 to 90oC
SO2 concentration in boiler flue gas = 4000 ppm (or mg/kg)
Solvent = 1 % lime solution
Solvent to gas ratio = 1.4 L/m3
Throat velocity of gas phase = 100 m/s
Average molar mass of flue gas = 29.48 kg/kmol
Solution:
Volumetric flow rate of gas at actual operating condition.

24 000
qw = x (273 + 90) = 31 912.1 nvVh
v
273
= 8.8645 m3/s
Gas velocity in throat = 100 m/s
Inside diameter of throat.

'4x8.8465
d. = = 0.336 m
TT X100

Flow rate of solvent (1% lime solution) = 1.4 x 8.8645 = 12.41 Us = 44.676 nrVh
Density of 1% lime solution = 1012.5 kg/m3
Mass flow rate of solution = 45 234.5 kg/h
mL = 12.565 kg/s

12.565
Molar flow rate of Liquid, LM = = 0.693 kmol/s
1
(0.99/18)+ (0.01/74)

Pdv 1 x 8.8645
Molar flow rate of Gas, GM =
RT 0.082 x( 273+ 90)
Process Engineering Channel

= 0.2978 kmol/s
Number of transfer units, Nc that can be achieved in venturi scrubber is in the range of
1 to 2.
Assuming iVG = 1 (safe value)
Mass transfer efficiency,

n=l - e-No
@ProcessEng

11 = I - e-NE =[-e-] = 0.6321 (9.38)

Fractional solute removal,

(1 - mx2/y2)
1 - ZL = E
r
M
1 +m
I '
Aw /
 614 Introduction to Process Engineering and Design

Gm Gm / Flow area GM 0.2978

= 0.43
Lm/Flow area LM 0.693
j:2 = 0, ^2 = ?

^ £ 0.6321
Ji . G^ 1 +0.43 m
1 + m——
Lm
yl = 4000 x 10-6 = 0.004
Partial pressure of SO2 in gas phase s 0.004 x 760 = 3.04 ton-
Assume the average temperature of scrubber = 50oC
Equilibrium mass of SOj per 100 mass of PEO = 0.035
(Table 3-144 ofRef. 3)

Equilibrium mass fraction = = 3.5 x lO-4

100.035

3.5 x 10_4/64
Equilibrium mole fraction =
(3.5 xl0-4/64) + ( 1-3.5 xl0"4)/18

x(. = 9.846 x lO"5

y, = 0.004

Q QQ4
m = ' = 40.63
9.846 xl 0"5
Equilibrium constant for physical absorption at 50oC and 1 atm pressure, m = 40.63
For low concentration range m can be assumed constant.

1-i^= °^21 = 0.034 22

yl 1 + 0.43 x 40.63

yi
— = 0.9658
Ei
^2 = 0.003 86
Here, presence of 1 % lime in solution or chemical reaction between lime and SCE is not
Process Engineering Channel

considered. Chemical reaction enhances the rate and extent of absorption considerably.
To find this, lab-scale or pilot plant scale data are required on the same system and also
on the same type of absorber. Reliable theoretical equations are not available for the
same.
Pressure drop
/ , , \0-78
AP = 2.584 x lO"3 v* pG A®1331 ^7 1 (9.40)
@ProcessEng

vG = 100 m/s

Alh = Throat area in cm2 = (33.6)2 = 886.7 cm2

 Process Design of Absorbers

Density of gas, pG kg An3

pm 1 x 29.48 ,
pa = = = 0.99 kg/m3
RT 0.082 x( 273+ 90)

a: = i.4-l
G' m3
AF = 82 cm WC = 820 mm WC
Comparison with spray absorber:
Pressure drop provided by venturi scrubber (820 mm WC) is very much greater than the
same provided by vertical spray absorber (64 mm WC).

9.6 PROCESS DESIGN OF FALLING FILM ABSORBER8 9

Falling film absorber is a shell and tube heat exchanger in which absorption of
gas in liquid is carried out inside the tubes while cooling medium like cooling
water is circulated on the shell side. It is used for highly exothermic absorption
like absorption of hydrogen chloride gas in water, absorption of ammonia gas in
water, absorption of sulphur trioxide in alpha olefins, absorption of sulphur tri-
oxide in methyl esters of saturated fatty acids, etc.

9.6.1 Advantages of Falling Film Absorber Over Packed

Tower Type Adiabatic Absorber

(i) Falling film absorber gives better quality of product solution. Concentra-
tion of HC1 in product solution from falling film absorber is 35% to 37%
(by mass), while the same from adiabatic packed tower ranges from 25% to
30%.
(ii) Absorption is more efficient in falling film absorber for the given absorp-
tion duty. Falling film absorber requires less space compared to adiabatic
packed tower type absorber.
(iii) Other advantages of falling film absorber are lower temperatures, lower
pressure drops and higher turn down.

9.6.2 Disadvantages of Falling Film Absorber

Process Engineering Channel

(i) More difficult to control and is sensitive to liquid and gas distribution prob-
lems.
(ii) It has greater tendency to absorb undesirable water soluble low boiling
impurities.

9.6.3 Exothermic Absorption of Gases Like HCI and NH3

@ProcessEng

In case of exothermic absorption of gas like HCI and NH3 in water, there are two
requirements
(i) Large liquid surface area to gel the higher rate of mass transfer
(ii) Rapid removal of the heat of absorption
Both can be done most effectively by causing the liquid to flow down as a film
inside of a vertical tube which is cooled on the outside.
 Introduction to Process Engineering and Design

Falling film absorber with counter current flow of the gas and liquid suffer
from the limitation that flooding occurs when the gas velocity exceeds a limiting
value of the order of 4.5 m/s for 25 mm OD tube. A sample calculation shows
that at the usual ratio of liquid and gas flow rates, the liquid rate is barely sufficient
to maintain a liquid film on the tube wall. Hence counter current contact is not
preferred. Cocurrent contact of gas and liquid allows the gas velocity up to 18 m/s.
For the absorption of hydrogen chloride gas falling film absorber (with cocurrent
contanct of gas and liquid) followed by tail gas scrubber is preferred if the
concentration of hydrogen chloride gas in feed gas mixture is more than 40% (by
mole). Nearly 66 to 85% of absorption is carried out in falling film absorber
while the balance is carried out in the tail gas scrubber. If the concentration of
hydrogen chloride in feed gas mixture is less than 40% (by mole), then it is difficult
to produce the product solution of commercial strength. With cocurrent contact,
partial pressure of hydrogen chloride in exist gas is greater than or equal to exit
gas equilibrium partial pressure of hydrogen chloride in product solution.
While most HC1 gas will be scrubbed in these two scrubbers, local environ-
mental standards could mendate an additional vent scrubber in which final wash
of the outgoing gas mixture is carried out by spraying small quality of water.
However, the bottom solution from the vent scrubber will contain some HC1 and
its disposal may require neutralization with alkali.
Low concentraction of HC1 in exist gas gives low concentration of HC1 in
product solution. The arrangement of falling film absorber with tail gas scrubber
is shown in Fig. 9.14.
Feed gas and weak acid from the tail gas scrubber (5 to 10% HC1 solution) is
supplied at the top head of falling film absorber. Tubes are extended above the
top tube sheet to facilitate the uniform distribution of liquid in each tube. Notches
may be cut in the top ends of the tubes. Tubes are made from graphite, glass or
tantalum. As per the recommendations tubes must be extended at least by
125 mm above the top tube sheet to minimize the effect of hydraulic gradient in
the liquid. With cocurrent contact in upper portion of tubes, rate of absorption is
very high. It may lead to the overheating of tubes in upper portion. Overheating
breaks the glass tubes. To avoid this, inverted U in the discharge line of water is
Process Engineering Channel

essential. Inside the lubes there is a two phase flow of liquid and gas in which
liquid forms the film over the inside periphery of tubes while gas flows in the
central portion. Absorption of gas in liquid film generates the heat. Temperature
of liquid film is controlled by cooling water circulated on shell side. In the bot-
tom head, gas and product solution are separated. Exist gas is in the equilibrium
of product solution at outlet condition. Hence, complete absorption of HC1 with
@ProcessEng

this arrangement is impossible. Remaining HC1 is absorbed by contact with pure

water in tail gas scrubber which is commonly used and is normally a packed
tower type absorber.
 Process Design of Absorbers

FRC
Nf -

Water Tail gas

PIC scrubber

Feed

Water

Vent scrubber

900
Cooling
water out Seal
loop
TRC

HC1
falling film o
o
absorber fN

Cooling
water In

Bypass gas line

Seal 32% or 35%

4500 loop HC1 solution
to storage
Process Engineering Channel

SC

Fig. 9.14 Typical Falling Film Absorption System

9.6.4 Process Design of Falling Film Absorber

@ProcessEng

Consider absorption of HC1 in water.

(i) Fix the inlet and outlet concentrations of hydrochloric acid. Also, fix the
concentration of hydrogen chloride in the exist gas stream. Partial pressure
of hydrogen chloride in the exist gas stream at bottom should be greater
than vapour pressure of hydrogen chloride in product solution at outlet
 Introduction to Process Engineering and Design

temperature. Based on this fact, outlet temperature and concentrations of

liquid and gas streams can be fixed.
(ii) Determine the overall rate of absorption and based on the same, determine
the total heal duty. Actually rale of absorption and hence rate of heat transfer
required are changing from point to point of the heat exchanger (i.e. falling
film absorber)
(iii) Based on the heat balance, find the flow rate of cooling medium.
(iv) In the end, heat transfer area of falling film absorber must be determined

0
A = N, k cLL = —-— (9.41)
U ATm

To facilitate two phase flow, d0 (tube outside diameter) can be selected as 25.4
mm. Number of tubes must be decided based on following criteria
(a) For cocurrent contact velocity of feed gas mixture at inlet should be less
than or equal to 18.3 m/s. To get the higher rate of mass transfer gas veloc-
ity at tube, inlet should be around 15 m/s as per the recomendations. (p. 409
of Ref. 8)
(b) For efficient operation of falling film absorber certain minimum liquid flow
rate is required to maintain a continuous film over the tube wall. Minimum
required flow rate of liquid is 150 kg/(h • m), i.e. m of inside periphery of
tubes.
Actually once velocity of gas is fixed, flow rate of liquid per unit periphery of
tube is fixed by material balance and reverse is also true.
Tube length can be easily determined based on average value of overall heat
transfer coefficient U and based on the overall values of heat duty (0) and overall
mean temperature difference {ATm) (difference between temperature of liquid
film and temperature of water). Actually rate of absorption, rate of heal transfer,
overall heat transfer coefficient and temperature difference across the heat transfer
wall are changing from point to point. Hence, for the precise calculations, heat
exchanger can be divided in different zones and for each zone, tube length is
determined. For each zone, rate of absorption, heat duty and mean temperature
difference are calculated. Over all coefficient U is assumed as constant. In trial
Process Engineering Channel

and error calculations, film temperature is assumed. Based on that rate of

absorption per unit area, heat duty per unit area and are calculated. Check 0/
A = f/ACT. Rale of absorption of gas is given by equation.

Rate of absorption, NA = KGM( pAG - pAL ) kg/(m- ■ s) (9.42)

where, KG = Overall mass transfer coefficient based on the arithmetic mean
@ProcessEng

partial pressure difference in kmol/(m • atm ■ s)

M = Molar mass of gas absorbed kg/kmol = 36.5 for HC1 or 17 for
NH3
pAG = Partial pressure of solute gas in gas mixture, atm
 Process Design of Absorbers

pAL = Equilibrium partial pressure of solute A at gas liquid interface,

atm
Mass transfer coefficient for hydrogen chloride absorption in the tubular absorber
is calculated by following equation8

1.654x KT5 (djG,

Kn = kmol/(m- • atm ■ s) (9.43)
75
Mlv V ^

where, d: = Inside diameter of tube, m

G, = Mass velocity of gas mixture at inlet, kg/(m ■ s)
p = Viscosity of gas mixture kg/(m • s)
Mav = Average molar mass of gas mixture at inlet, kg/kmol
Heat transfer coefficient of liquid film can be calculated by McAdams, Drew and
Bay's equation (Ref. 8).
h = 9136 x t1/3 (9.44)
0
where, h = Tube side heat transfer coefficient, W/(m • C)
z= Liquid flow rate per unit periphery, kg/(m • s)
This correlation is valid for values of T, ranging from 0.25 to 6.2 kg/(m ■ s)

Example 9.4
Gas mixture, obtained after the chlorination reaction and separation of organic vapours,
contains 20% CL and 80% HC1 by mole. From the mixture, hydrogen chloride gas is to
be separated by absorption in water. For the absorption of HC1, falling film absorber,
followed by tail gas scrubber are used. Design the falling film absorber.
Flow rate of gas mixture = 2500 kg/h
Temperature of gas mixture = 10oC
% of HC1 in the liquid stream leaving the tail gas scrubber and entering at the top of
falling film absorber = 5% (by mass)
Desired concentration of HC1 in product stream = 32% (by mass )
Operating pressure = 30 kPa g (at inlet)
Solution:
Amount of product solution = qm kg/h
HCI balance
Process Engineering Channel

0.8x36.5
2500 x = qm x 0.32
0.8x36.5 + 0.2x71

2500 x 0.6728 = qm x 0.32

qm = 5256.25 kg/h
Tail gas scrubber is operated in adiabatic manner. Hence, the total heat of solution of
hydrogen chloride in water (which is highly exothermic) is removed in falling film
@ProcessEng

absorber to maintain nearly isothermal condition. Heat duty of falling film absorber can
be calculated based on heat of formation data of aqueous hydrochloric acid solution
(Table 9.7).
Heat of formation of aqueous-hydrochloric Acid (Table 5.53 of Ref. 10)
Heat of solution = (AHfu) of 32% solution - (AHj) of HCI gas
 Introduction to Process Engineering and Design

PIC

Feed

5%
HC1 solution

Cooling
water out
Seal
loop

Falling film
absorber

Cooling
water in

Point 1 Exit gas mixture

Seal 32%
loop
FIC1 solution
to storage
Process Engineering Channel

SC

Fig. 9.15 Falling Film Absorption System

@ProcessEng

Heat of formation of 32% HC1 solution = -153.9 kJ/mol HC1

Heat of solution = (-153.89) - (-92.31) = -61.58 kJ/mol HC1

2500x0.6728
Moles of HC1 absorbed = = 46.082 kmol/h
36.5
 Process Design of Absorbers 621

Table 9.7 Heat of Formation of Aqueous Hydrochloric Acid Solution10

Formula State Heat of formation (AHf0) Mass % HC1 in aqueous

at 298 K, kJ/mol HC1 solution

HCI. 75 H20 aq -165.72 2. 63

HCI. 50 H20 aq -165.36 3. 90
HCI. 40 H20 aq -165.10 4. 82
HCI. 30 Hp aq -164.67 6. 33
HCI. 25 H20 aq -164.34 7. 50
HCI. 20 H20 aq -163.85 9. 21
HCI. 15 H20 aq -163.03 11. 9
HCI. 10H2O aq -161.32 16. 9
HCI. 8 H20 aq -160.00 20. 2
HCI. 6 H20 aq -157.68 25. 3
HCI. 5 H20 aq -155.77 28. 9
HCI. 4 H20 aq -152.92 33. 6
HCI. 2 H20 aq -140.96 50. 3
HCI. H20 aq -121.55 67. 0
HCI gas -92.31 100.0

Note: The number in the first column indicates the number of moles of water mixed
with one mole of hydrogen chloride.
Heat duty of falling film absorber (including that of tail gas scrubber),
(pt = 61.58 x 1000 x 46.082 = 2837 729.6 kJ/h = 788.26 KW
(Actually in falling film absorber, concentration of HCI in aqueous solution is increased
from 5% to 32% but tail gas scrubber is operated in adiabatic manner hence heat of
solution generated on increasing the concentration from 0 to 5% of HCI is to be added in
heat duty of falling film absorber)
Temperature of 5% weak acid:
Heat of formation for 5% HCI solution = -165.05 kJ/mol
Heat of solution = (-165.05) - (-92.31) = -72.74 kJ/mol
Moles of HCI absorbed in adiabatic absorber
/
46.082 x 36.5
--46.082x36.5 xM3x, 1
0.32 0.95 36.5
Process Engineering Channel

= 5.154 kmol/h
= 188.121 kg/h
Heat generated in adiabatic absorber
0, = 72.74 x 1000 x 5.154 = 374 902 kJ/h = 104.14 kW
Mass flow rate of pure water entering to adiabatic absorber = Mass flow rate of 32%
solution x (1 - 0.32)
@ProcessEng

qw = 5256.35 x (1 - 0.32) = 3574.25 kg/h

Mass flow rate of 5% HCI solution

=
3574 25 = 3762.37 kg/h
lvl
(1-0.05)
Enthalpy of 5% solution
 Introduction to Process Engineering and Design

= Enthalpy of pure water + Enthalpy of incoming gas mixture - Enthalpy of exist gas
from adiabatic absorber + Heat of solution
Let reference temperature = 30oC
Here pure water enters at room temperature or at a temperature close to 30oC. Tempera-
ture of incoming and exist gas mixture are also close to 3G0C. Heat of solution must be
determined at average temperature. Neglect the change in the value of heat of solution
with temperature.
Heat capacity of 5% solution = 4.19 kJ/(kg ■ 0C)
Enthalpy of 5% solution = qw ■ CL (t - 30)
3762.37 x 4.19(7 - 30) = 374 902 kJ/h
t = 53.780C
Mass flow rate of cooling water:
Let inlet temperature of cooling water to absorber = 320C and outlet temperature of
cooling water from absorber = 380C
Mass flow rate of cooling water,

q... - ^ = 788.26 o.^n.kg/s

= 31.379 /
ClM 4.1868 x (38-32)
= 112 964.4 kg/h
Material of tube = Graphite
Outside diameter of tube dn = 25 mm
Inside diameter of tube d, = 20 mm
It is reported in literature that if the velocity of gas through the tubes is kept more than
15.24 m/s, then higher tube side or film side heat transfer coefficient is obtained. There
is a sharp increase in the tube side heat transfer coefficient when the velocity of gas at
the tube inlet exceeds 15.24 m/s.
Let the velocity of gas at tube inlet =16 m/s
Average molar mass of feed gas mixture at inlet
Mav = I(M,. - >•,) = 0.2 x 71 + 0.8 x 36.5 = 43.4 kg/kmol
Density of feed gas at inlet
pM (30 +101.325 )x 43.4 273
P
~~RT~~ (273 + 10) ~ 101.325x22.414
p = 2.42 kg/m3
Process Engineering Channel

Volumetric flow rate of gas mixture at tube inlet, qv =

qv = 1033 m3/h

Velocity of gas at tube inlet, v= -

N, x

1033/3600
N, = = 57
@ProcessEng

2
16 x —(0.02)
4
Tube side mass velocity, C, = m, p = 16 x 2.42 = 38.72 kg/(m2 • s)
Tube side heat transfer coefficient:
Tube side or falling film side heat transfer coefficient
h: = 9136 x t"3 (9.44)
 Process Design of Absorbers 623

where, hi is in W/(m2 ■ 0C)

T = Liquid flow rate per unit periphery, kg/(m • s)

Liquid flow rate at inlet = 3762.37 kg/s = qW[

= _ 3762.37/3600
N, k di 57 x tt x 0.02

T = 0.2918 kg/(m ■ s) (= 1050.5 kg/(m • h) > 150 kg/(m ■ h))

hi = 9136 x (0.2918)l/3 = 6059.7 W/(m2 ■ 0C)
Shell side heat transfer coefficient

{Pt-d0)B, D,
Shell side flow area, As = —:—- (6.29)
Pi
P, = Tube pitch = 1.25 d0 = 1.25 x 25 = 31.25 mm, d0 = 25 mm
Tube bundle diameter

Db - dp (6.1)
\ i /
For PJd0 = 1.25, triangular pitch, 1-1 shell and tube fixed tube sheet heat exchanger,
kx = 0.319, n, = 2.142 (From Table 6.2)
i
2142
D, = 25| _5Z_ = 281.4 mm
0.319,
Ds = Db + 18.6 mm = 300 mm. Let Bs = 100 mm

(31.25-25) ,
Ac = x 0.1 x 0.3 = 0.006 m2
5 31.25
Shell side equivalent diameter

de = ^-( pj - 0.907 d];) (6.32)

do

= — (3L252 - 0.907 x 252) = 18.026 mm

25
Process Engineering Channel

Shell side mass velocity, G? = — = = 5229.8 kg/(m2 • s)

5
A, 0.006

G. S229 8
1
Shell side velocity, tic = = — = 5.26 m/s > 3 m/s (too high)
^ 5 p 994.032
For the liquid flow on shell side, it is better to restrict the shell side velocity below
@ProcessEng

3 m/s to avoid the liquid induced vibrations.

Change the baffle spacing from 100 to 300 mm.
Bs = 300 mm

31.25-25
Ac = x 0.3 x 0.3 = 0.018 m2
31.25
 Introduction to Process Engineering and Design

31.379
Shell side mass velocity, Gs = = 1743.3 kg/(m2 • s)
0.018

1743.3
us = = 1.7538 m/s
P 994.032
deGs 0.018 026x1743.3
Shell side Reynolds number. Re = = 39 280.9
P (0.8 xIO-3)
(Viscosity of water at 350C, fu = 0.8 cP)
Prandtl number for water at 350C

CPH 4.1868 x (0.8 x 10-3) x 103

Pr= —— = =5.333
k 0.628
Evaluation of h0 (shell side heat transfer coefficient):
0.14
= 0.36 Re0 55 P/s>-33 (6.35)
Piv
,0.14
0.628 _P_
h. = 0.36 x x (39 280.9) ' 0 55
x (5.333)'\0.33 X
0.018 026 \Pw /

_P_
where
Pw
h0 = 7329.3 W/(m2 • 0C)
Overall heat transfer coefficient

I 1 1
d0 ln( d0 /di) d0 1^1 do
+- •+—x +—x (6.42)
U
o K hod 2kw d, h:id di ^
Fouling coefficients, hod = hid = 5000 W/m2 • 0C)
Thermal conductivity of graphite = 150 W/(m • k) from Appendix of Ref. 11.
( 25
J
0.025 In
_l_ 1
20 25 1 25 1
+^ + +—x + — x-
Uo 7329.3 5000 2x150 20 5000 20 6059.7
,2
Un = 1232.6 W/(mz ■ 0C)
The temperature of the acid film on inside surface of tubes attains an equilibrium value
Process Engineering Channel

at which the rate of heat transfer to the cooling water balances the rate of heat release
due to absorption. This temperature is calculated by trial-and-error method for a series
of points in the absorber.
Point 1: Bottom most point of tubes: At this point aqueous acid film concentration of
liquid film is 32% (by mass). Liquid composition at point 1.

Table 9.8 Composition of Bottom Solution (Point I)

@ProcessEng

Component kg/h mass % kmol/h

HCI 1682.00 32 46.082

H20 3574.25 68 198.570
Total 5256.25 100 244.650
 Process Design of Absorbers

HC1 amount in 5% acid stream = 188.12 kg/h

HC1 balance around falling film absorber:
HQ in exist gas stream = HQ in inlet gas stream + HQ in 5% acid stream
- HQ in product stream
HQ in exist gas stream = 2500 x 0.6728 + 188.12 - 1682 = 188.12 kg/h
Q2 in exist gas stream = 2500 ( 1 - 0.6728) = 818 kg/h

Table 9.9 Gas Composition at Point I

Component kg/h mass % kmol/h mole %

HCI 188.12 18.7 5.154 30.91
ci2 818.00 81.3 11.520 69.09

Total 1006.12 100.0 16.674 100.00

Partial Pressure of HQ gas in gas mixture at point I

= x =
Pag Pi Thci 131.325 x 0.30 966 = 40.666 kPa = 0.4013 atm

Equilibrium Partial Pressure of HQ ( pXl ):

Equilibrium Partial Pressure of HQ gas over aqueous solution of Hydrochloric acid can
be calculated by following equation

log Pal = ^ -

where p*xf is in torr and T in K (Table 3.11 of Ref. 3)

Table 9.10 Antoine Equation Constants3

% HCI by mass 4 B

2 11.8037 4736
4 11.6400 4471
6 11.2144 4202
8 11.0406 4042
10 10.9311 3908
12 10.79 3765
Process Engineering Channel

14 10.6954 3636
16 10.6261 3516
18 10.4957 3376
20 10.3833 3245
22 10.3172 3125
24 10.2185 2995
26 10.1303 2870
@ProcessEng

28 10.0115 2732
30 9.8763 2593
32 9.7523 2457
34 9.6061 2316
36 9.5262 2279
 Process Design of Absorbers 627 |

Rate of heat transfer at point 1 between acid film and cooling water

= [/At = 1232.6 x (35.5 - 32) = 4314.1 W/m2 =4.314 kW/nr

Heat release due to absorption ^ f/Ar

2nd trial:
Let acid film temperature at point 1 = 36.50C
Equilibrium partial pressure of HC1 for 32% solution at 36.50C:

Pal = 65.116 torr = 0.0857 atm

Heat release due to absorption = 2.8233 x 10"4 x 36.5 (0.4013 - 0.0857)
= 3.252 x lO"3 kg/(m2 ■ s)
Heat release due absorption = 3.254 x IO"3 x 1687.12 = 5.49 kW/nr

— = UAt= 1232.6 x (36.5 - 32) = 5546.7 W/m2 = 5.546 kW/m2

4
Heat release due to absorption = UAt
Temperature of acid film at point I = 36.50C
Point 2: At this point concentration of Acid film is 26% (by mass).

5256.25 x 0.68
Mass flow rate of 26% HC1 solution = = 4830.07 kg/h
(1-0.26)
Amount of HC1 absorbed in between point 1 and 2 = 5256.25 - 4830.07 = 426.18 kg/h
Composition of liquid mixture at point 2:

Table 9.1 I Liquid Composition at Point 1

Component kg/h mass %

HC1 1255.818 26
Water 3574.25 74
Total 4830.07 100

Table 9.12 Composition of Gas Mixture at Point 2

Component kg/h kmol/h mole %

Process Engineering Channel

HC1 614.3 16.83 59.365

CL 818.0 11.52 40.635
Total 1432.3 28.35 100

For the first trial calculations let the temperature of 26% acid film at point 2 = 40oC

log pi, = 10.1303 ^—

(40 + 273)
@ProcessEng

=
Pal 9-14 torr = 0.012 atm
x
Pag = Thci Pt = 0-593 65 x 131.325 = 77.96 kPa = 0.7694 atm
Average molar mass of gas mixture
Mav = ZOvM,) = 0.593 65 x 36.5 + 0.403 35 x 71 = 50.306 kg/kmol
Mass velocity of gas mixture
 Introduction to Process Engineering and Design

G,= — = 1432.3/3600 = 22.218 kg/(m2 ■ s)

a
' 57 x —(0.02 )2
4
At point 2

1.654x10 -5 diGt 1.654x10,-5 0.02 x 22.218 x

Kr X
G= Ml.75
av 50.3061'75 0.0145 xl 0"3 y

(At 40oC, /dcu = 0.0145 cP, fiHCl = 0.0145 cP)

Kg = 5.334 x 10-4 kmol/(atm ■ m2 • s)

Rate of absorption, NA = KGM ( pAG - pAL)

Na = 5.334 x lO"4 x 36.5 x (0.7694 - 0.012) = 0.014 746 kg/(m2 • s)

Heat of solution for 26% HC1 solution
-
AHS = (A/y/")26%HCI (AT//" )hci gas
= (-157.3) - (92 .31) = -65 kJ/mol
= -65 000 kJ/kmol =-1780.82 kJ/kg
Heat release due to absorption (per unit area)
<p = NAx i-AHs) = 0.014 746 x 1780.82 = 26.26 kW/m2
Heat duty required in between 1 and 2
0,2 = Total heat duty of falling film absorber - Heat duty required to form
26% HCI solution
0,2 = 788.26 kW - (-AHS) x kmol/h of HCI absorbed to form 26% solution

426-18
0,2 = 788.26 - 65000 x | 46.082 - |x 1
36.5 J 3600
= 167.0435 kW = qcw CL(t - 32)
167.0435 = 31.379 x 4.1868 x (t-32)
Temperature of cooling water at point 2, t= 33.270C

<
^ = UAt= 1232.6 x (40 - 33.27) = 8295.4 W/m2 = 8.295 kW/m2

= 8.295 kW/m2 ^ Heat release due to absorption.

Process Engineering Channel

2nd trial
Let temperature of 26% acid film at point 2 = 540C
Equilibrium partial pressure of HCI over solution

i -* i n i ono 2870
log Pai = 10.1303
(54 + 273)
@ProcessEng

pAL = 22.57 torr = 0.0297 atm

At 540C, pHa = ^ = 0.015 cP (Fig. 3.14 of Ref. 3)

Kg = 5.334 x lO"4 x 0 0145

' = 4.9899 x lO"4 kmol/(m2 ■ atm • s)
0
0.0155
Na = 4.9899 x lO"4 x 36.5 x (0.7694 - 0.0297) = 0.013 47 kg/(m2 • s)
 Process Design of Absorbers 629

Heat release due to absorption = 0.013 47 x 1780.82 = 23.9876 kW/m2

^ = UAt= 1232.6 x (54 - 33.27) = 25 551.8 W/m2 = 25.55 kW/m2

A
3rd trial
Let temperature of 26% Acid film = 52.50C

plL = 20.563 torr = 0.027 atm

Na = 4.9899 x lO"4 x 36.5 (0.7694 - 0.027) = 0.013 52 kg/(m2 ■ s)
Heat release due to absorption = 0.013 52 x 1780.82 = 24.076 kW/m2

— = U At = \ 232.6 x (52.5 - 33.27) = 23 703 W/m2 = 23.7 kW/nr

A

— = U Ar = Heat release due to absorption

Temperature of acid film = 52.50C

Heat transfer between point 1 and 2:
012 = 167.0435 kW, U0 = 1232.6 W/(m2 ■ 0C)

(52.5-33.27)-(36.5-32)
A "4 = : = 10.142oC
52.5-33.27
In
36.5-32

0,21 167.0434 xl 03 ,
Area required A,2 = — = 13.362 m-
U0A'r]n 1232.6x10.142

Ntnd0 Ln = An = 13.362 m2 or = 2.984 m

0 12 12 12
' 57 x tt x 0.025
Point 3: At this point acid film contains 20% by mass HC1
Let liquid film temperature at point 3 = 680C

Table 9.13 Liquid Composition at Point 3

Process Engineering Channel

kg/h mass % kmol/h

HC1 893.56 20% 24.48
H20 3574.25 80% 198.57
4467.81 100% 223.05

Table 9.14 Gos Composition at Point 3

@ProcessEng

kg/h kmol/h mole %

HC1 976.56 26.755 69.9

Cl2 818.00 11.52 30.1
1794.56 38.275 100%
 630 Introduction to Process Engineering and Design

Equlibrium partial pressure of HQ over 20% HQ solution

3245
log p*AL = 10.3883 - = 10.3833 -
T (273 + 68)

Pal - 7.365 torr = 0.0097 atm

Pal =Ptx >'hci = ■

131 325 x 0 699
- = 91 8 kPa
= 0-906 atm

Average molar mass of gas mixture,

Mav = = 0.699 x 36.5 + 0.301 x 71 = 46.885

Mass velocity, G, = —^ 7 )4.56/3600 _ 23^375 kg/(m2 ■ s)

57 x (7r/4)(0.02)

At 680C, /u = iiuo = Ha, =

0-0162 cP

1.654x10 -5 djG.
A
1.654 xlO-5 0.02 x 23.8375
Kr -x
G= mI.75
av P 46.8 851 75
\ 0.0162 xlO
-3
/
Kc = 5.7943 x lO"4 kmol/(atm • m2 • s)
Rate of absorption.

Na=KgM{ pag - pAL ) = 5.7943 x lO"4 x 36.5 x (0.906 - 0.0097)

= 0.018 956 kg/(m2 • s)

Heat of solution of 20% HQ solution A//s = (-160.08) - (-92.31)
A/yv = -67.77 kJ/mol = -67 770 kJ/mol = -1856.7 kJ/kg
Rate of heat generated due to absorption - NAx (-A//v)
= 0.018 956 x 1856.7 = 35.1956 kW/m2
Amount of HQ absorbed in between point 3 and 2 = 362.26 kg/h
Heat duty required in between point 2 and 3
023 = 0;- 0i2 ~ Heat required to form 20% HQ solution
Heat required to form 20% HQ solution = -A7/s x 893.56 kg/h
= 1856.7 x 893.56 = 1659 072.9 kJ/h = 460.85 kW
= 788.26 - 167.044 - 460.85 = 160.366 kW
= 160.336 kW = qcw ■ CL{t-33.27)
Process Engineering Channel

160.336 = 31.379 x 4.1868 x (r - 33.27)

t = 34.490C = Temperature of cooling water at point 3

— = UAt= 1232.6 x (68 - 34.49) = 41 304 W/m2 = 41.304 W/m2

A
+ Rate of heat generated due to absorption
Ilnd trail: Let the temperature of 20% Acid film at point 3 = 630C
@ProcessEng

log p;L = 10.3833-

(63 + 273)

=
Pal 5.3157 torr = 0.007 atm

At 630C, p = Hna = Pa2 = 0.0161 cP

 Process Design of Absorbers 631

Kg = 5.7943 x lO"4 x 0 0162

- = 5.8303 x lO"4 kmoy(atm • m2 • s)
G
0.0161
Temperature of acid film = 52.50C
Na = 5.8303 x lO"4 x 36.5 x (0.906 - 0.007) = 0.019 13 kg/(m2 • s)
Rate of heat generated due to absorption - NAx (-AHS)
= 0.019 13 x 1856.7 = 35.52 kW/m2

j = UAr= 1232.6 x (63 - 34.49) = 35 141 W/m2 = 35.141 kW/m2

0
— = U At = Rate of heat genetrated due to absorption

Temperature of acid film at point 3 = 630C

023 = 160.336 kW, U = 1232.6 W/(m2 • 0C)

(63-34.49)-(52.5-33.27)
A'4 = = 23.5660C
/ N
63-34.49
In
52.5-33.27

013 160.336 x 103

A-,-, = —-— = = 5.5198 nr =N, Kdn L-,-,
UAT[a 1232.6x 23.566

57 x ttx 0.025 x L23 = 5.5198 m2

L23 = 1.233 m
Point 4: Assume that at this point acid contains 12% HC1.

Table 9.15 Liquid Composition at Point 4

kg/h mass %

HCI 487.4 12
H20 3574.25 88
4061.65 100

Table 9.16 Gas Mixture Composition at Point 4

Process Engineering Channel

kg/h mass % kmol/h mole %

CI2 818 37.17 11.52 23.32

HCI 1382.72 62.83 37.883 76.68
2200.72 100 49.403 100

Let temperature of acid film at point 4 = 720C

@ProcessEng

Equilibrium partial pressure of HC1 over 12% HCI solution

log p* = 10.79 - = 10.79 ——

T (273 + 72)
= 0.753 torr = 9.9 x 10"4 atm
 Introduction to Process Engineering and Design

xP
Pag = yuci , = 0-7668 x 131.325 = 100.7 kPa = 0.9938 atm
Mav = = 0.7668 x 36.5 + 0.2332 x 71 = 44.55 kg/mol

2200.72/3600
G,= = 34.138 kg/(m ■ s)
51 x (7r/4)(0.02)'
Mass transfer coefficient

1.654x10i-5 djG,
KG =
M 1.75 P
0
At 72 C,

P = Phc\= PCU = 0.0163 cP

1.654x10,-5 0.02x34.138
KG = X = 9.0185 x 10-4 kmol/(m- • atm • s)
1.75 -3
44.55 0.0163x10
Rate of absorption

Na = KgM ( pAG - pAL) = 9.0185 x 10^ x 36.5 (0.9938 - 9.9 x 10^)

= 0.032 68 kg/(m2 • s)
Heat of formation of 12% HC1 solution = -163 kJ/mol
Heat of solution of 12% HC1 solution

AHs = {AHJ )]2%, HCI ~ )HCIgas

= -163 -(-92.31) = -70.69 kJ/mol = -70 690 kJ/mol s - 1936.7 kJ/kg

Heat release due to absorption
= 0.032 68 x 1936.7 = 63.29 kW/m2
Heat duty required in between points 3 and 4
=
034 0f_0i2-023- Heat duty required to form 12% HCI solution

<t)M
34
= 788.26 - 167.044 - 160.366 - (1936.7 x 487.4) x
3600
= 198.64 kW = qcw C, At34 = 31.379 x 4.1868 x(t- 34.49)
t = 360C = Temperature of cooling water at point 4

= UAt = 1232.6 x (72 - 36) = 44 374 W/m2 = 44.374 kW/m-

A
Process Engineering Channel

Hence UAt -A heat release due to absorption

2nd trial
Let film temperature of 12% HCI solution = 850C

3765
log p*AL = 10.79
(85 + 273)
@ProcessEng

Pal = 1 -876 torr = 0.0025 atm

Viscosity of gas mixture // = 0.017 cP

Kg = 9.0185 x lO"4 x - _ = 8.647 x KT4 kmol/(m2 ■ atm • s)

0 Q16 3

0.017
Na= KgM{ pag - p*AL)\ = O
— * £ A*1 xr 10-
8.647 I A-4
4
x 36.5 x (0.9938 - 0.0025)
= 0.031 29 kg/(m2 • s)
 Process Design of Absorbers 633

Heat release due to absorption = NAx (-AHS) = 0.031 29 x 1936.7 = 60.6 kW/m2

- = UAt= 1232.6 x (85 - 36) = 60 397 W/m2 = 60.397 kW/m2

A
^ Heat release due to absorption
Let film temperature of 12% HC1 solution = 85.10C
=
Pal L889 torr = 0.0025 atm
Na = 8.647 x 10-4 x 36.5 x (0.9938 - 0.0025) = 0.031 287 kg/(m2 • s)
Heat release due to absorption = 0.031 287 x 1936.7 = 60.59 kW/m2

- = UAt= 1232.6 x (85.1 - 36) = 60 521 W/m2 = 60.52 kW/m2

A

<p
- = UAt = Heat release due to absorption

034 = 198.64 kW, U0 = 1232.6 W/m2

(85.1 - 36) - (63 - 34.49)

A'l = = 37.8770C
N
' 85.1-36
In
63 - 34.49

034 198.64 xlO3 ,

4,4 = —^— = = 4.2547 m = /V, tt dn LM
U0 AT|n 1232.6x37.877

, 4.2547 „ ni.
L-,. = = 0.95 m
51 xttx 0.025

Point 5: At this point concentration of Acid film is 5% HCI (by mass).

Table 9.17 Liquid Composition at Point 5

kg/h mass %

HCI 188.12 5
Process Engineering Channel

H20 3574.25 95
3762.37 100

Let film temperature of 5% HCI solution = 97.50C

For 5% HCI solution

log p'm. = 11-4272 -

@ProcessEng

=
Pal 0.5281 torr = 6.95 x 10_4 atm

pAC = 0.8 x 131.325 = 105.06 kPa = 1.0369 atm

A/av = 0.8 x 36.5 + 0.2 x 71 = 43.4 kg/kmol
 Introduction to Process Engineering and Design

( 2500 "l
V 3600 )
C,= — = 38.78 kg/(m2 ■ s)
57 x —(0.02 )2
4
Viscosity of gas mixture at 97.50C, ^ = 0.018 cP

1.654x10,-5 0.02x38.78
Kg = = 9.7116 x lO-4 kmol/(atm • m2 • s)
43.4 1.75 0.018x10
-3

Na =9.7116 x lO^x 36.5 x (1.0369 - 6.95 x 10"4)

Rate of heat generated due to absorption =NAx (~AHS)

= 0.03673 x 72.74 x 1000 x

36.5
2
= 73.2 kW/m
At point 5,

= UAr = 1232.6 (97.5 - 38) = 73 340 W/m2 = 73.34 kW/m

A
= Heat release due to absorption

Table 9.18 Gas Composition at Point 5

kg/h kmol/h mole %

HCI 1682 46.082 80

Cl2 818 11.521 20
2500 57.603 100

Equilibrium acid film temperature at point 5 = 97.50C

045 = 788.26 - 167.044 - 160.366 - 198.64
045 = 262.2 kW, U = 1232.6 W/(m2 ■ 0C)

(97.5-38) -(85.1-36)
= = 54.1340C
N
' 97.5-38
In
Process Engineering Channel

85.1-36 s

<t>45 262.2 xlO3

^45 - = 3.9295 m2
VoAT^ ~ 1232.6x54.134

^45 3.9295
= 0.878 m
@ProcessEng

^-45 -
V, nd0 57 x tt x 0.025

5 % HC1 solution enters the falling film absorber at 53.780C. Hence, it will absorb the
heat to reach equilibrium temperature (97.50C). Actually this direct heating of liquid
film will reduce some heat duty of heat exchanger. So, further addition in heat transfer
area is not required.
 Process Design of Absorbers 635 |

Table 9.19 Summary of Zonewise Calculations

Point % HC1 Water, kg/s Temperature Temperature Area, m2 Length from, m

of acid film of water 0C bottom

1 32 31.379 36.50C 32
2 26 31.379 52.50C 33.27 13.362 2. 984
3 20 31.379 63 0C 34.49 5.5198 1. 233
4 12 31.379 85. rc 36 4.2547 0.95
5 5 31.379 97.50C 38 3.9295 0.878
Total 27.066 6.045

Normally 10% excess area is provided.

Desired HTA = 27.066 x 1.1 = 29.773 m2
Since tube length of 6.65 m in carbate heat exchanger is not desirable, select two heat
exchangers with equal HTA in series.
HTA per heat exchanger = 29.773/2 = 14.9 m2
Let tube length be L.
57 x Lx tux 0.025 = 14.9
L = 3.328 m
Carbate tubes of length 3.328 m (min.) will have to be provided.
Comments:
For the given case, falling film absorber with galss tubes can be considered as another
option. But glass falling film absorber with once through operation for the given case
cannot be used. Conductive coefficient, offered by glass tubes, is very low hence it
will control the value of overall coefficient. For absorption of HC1 in water with once
through operation in glass tube heat exchanger, temperature of acid film in upper por-
tion of absorber reaches boiling temperature. However, glass falling film absorber can
be used for the given case with only recirculation of hydrochloric acid solution. To
reduce the acid film temperature, gas feed can be diluted by air. Recirculation of hy-
drochloric acid solution or addition of air in gas feed decreases acid film temperatures
but increases heat transfer area required for the falling film absorber.

Example 9.5
Process Engineering Channel

Design a sieve plate type absorber for the absorption of formaldehyde from the Reactor
Exit Gas Mixture by water to make 37% (by mass) of formaldehyde solution in water.
Material balance data around absorber of formaldehyde plant (Via Formox process) are
given as follows.
Reactor exit gas is at 110oC (from recuperative heat exchanger) and at 135 kPa a
pressure.
Enthalpies of reactor exit gas mixture, absorber outlet gas mixture, bottom product
@ProcessEng

solution and fresh water with reference to 298.15 K (250C) are 1141.77 kW, 295.38 kW,
216.35 and 32.17 kW respectively. Exothermic heat of solution of formaldehyde gas in
water is substantially independent of concentration and has a value of 62.75 kJ/mol
HCHO at 298.15 K up to a concentration of about 40% (by mass) of HCHO. Fresh water
enters at 30oC and product solution leaves the absorber at 50oC. Temperature of exit gas
from absorber is 50oC (Ref: 10)
 636 Introduction to Process Engineering and Design

Table 9.20 Stream Compositions Across Absorber10

Reactor Exit Gas Absorber Outlet Gas Bottom Product

Component kg/h mass % kg/h mass % kg/h mass %
CH,OH 40 0.09 nil — 40.0 0.44
6806.8 15.81 6806.8 17.21
n2 29 626.8 68.81 29 626.8 74.9
h2o 2766.0 6.42 2649.0 6.7 5649.1 62.56
HCHO 3341.3 7.76 Nil — 3341.3 37.00
co2 386.6 0.9 386.6 0.98
co" 27.7 0.07 27.7 0.07
H2 4.0 0.01 4.0 0.01
ch4 9.9 0.02 9.9 0.02
(CH3)20 45.5 0.11 45.5 0.11
Total 43 054.6 100.00 39 556.3 100.00 9030.4 100.00

Solution:
3341 3
Total moles of formaldehyde absorbed = ——— = 111.376 kmol/h
30
Heat of solution = 62.75 kJ / mol
Total heat evolved by absorption
= 111.376 x 62.75 x 1000 = 6988 844 kJ/h = 1941.35 kW
This exothermic physical absorption is carried out either in tray tower or packed tower
in actual practice. In packed tower or tray tower, recirculation streams are provided and
these recirculation streams are passing through, external coolers. Recirculation streams
are provided to control the temperature of absorption. To achieve the complete absorp-
tion, final contact of exit gas is with fresh water, which is fed from the top.
In tray tower, intercoolers are provided. These intercoolers may be shell and tube type or
plate type or spiral heat exchangers. Here tray tower with sieve trays is designed.
Total heat to be removed by coolers
= Total enthalpy in + Heat generated due to absorption - Total enthalpy out
= (1141.77 + 32.17) + 1941.35 - (295.38 + 216.35) = 2603.56 kW
Flow rate of fresh water fed at the top of tower = 5649.1 + 2649 - 2766 = 5532.1 kg/h
Absorption of formaldehyde in water is highly exothermic but it can be carried out
Process Engineering Channel

approximately in isothermal condition by using intercoolers and providing recirculation

streams.
Let the average temperature of absorption in the entire tower is 450C.
Consider the top most section of tower [Refer Figures (4.2) and (4.7)]. To achieve the
complete absorption of formaldehyde, gas mixture must be finally contacted with pure
water. Recirculation cannot be provided in the top most section. If dilute solution of
formaldehyde is fed from the top with fresh water, then it limits the concentration of
@ProcessEng

formaldehyde in the exist gas.

Assuming that the heat of solution is utilized only in increasing the temperature of
formaldehyde solution. Fix the temperature of formaldehyde solutions leaving the top-
most section is 60oC.
Enthalpy of solution leaving the top most (first) section - Enthalpy of fresh water
= Heat of solution x Formaldehyde absorbed in top section
 Process Design of Absorbers

/
5532.1n
3600 (5532.1x4.1868(30-25))
-Q (60-25)-
w, 3600
100

62.75x1000
5532 I ^
-^^--5532.1 (a)
30 x 3600 VV|
1-
Too
where, w, = Mass % of formaldehyde in solution leaving the 1st section
Specific heat of formaldehyde solution is given by following equation12.
CL = 4.1868 [1 - 0.005 34 vv + (0.004 + 0.000 Olvv) r] (b)
where, CL is in kJ/(kg ■ C), vv is mass%, t is temperature in C.
0 0

60 + 25
Here, t= = 42.50C and vv = vv.

CL = 4.9 - 0.0206 vv, (c)

From (a) and (c)

1.5367 1
(4.9 - 0.0206 vv,) (60 - 25) - 32.17 = 0.581 x 5532.1 -1
(I -0.01 vv,) 1-0.01 vv.

53.7845 I
(4.9 - 0.0206 vv,) - 32.17 = 3214.15 -1
1 — 0.01 vv, 1-0.01 vv.

By trial and error calculations

For vv, = 7.0, LHS = RHS = 242 kW
Hence mass % of formaldehyde in solution leaving the topmost (1st) section = 7.0 %
This solution is leaving at 60oC.
Provide the first intercooler to cool this solution from 60oC to 40oC by cooling water.
Heat duty of first intercooler.
(pi = m Cl(6() - 40)

5532.1
m = = 5948.5 kg/h = 1.6524 kg/s
1-0.01x7.0
Process Engineering Channel

40 + 60
Q = 4.1868 (1 - 0.005 34 x 7.0) + (0.004 + 0.000 01x7)

CL = 4.88 kJ/(kg 0C)

0, = 1.6524 x 4.88 (60 - 40) = 161.27 kW
Stream leaves the first intercooler and enters at the top of second section which is 7%
(by mass) formaldehyde solution at 40oC.
@ProcessEng

This stream is mixed with recirculated stream as shown in Figs (4.2) and (4.7).
Let recirulation ratio = R
Mass flow rate of recirculated stream = Rx 1.6524
Total mass flow rate of formaldehyde solution feed to the top of the second section
= (R+l)x 1.6524.
% by mass of formaldehyde in liquid solution leaving the second section = 37%
 Introduction to Process Engineering and Design

Mass flow rate of formaldehyde solution leaving the second section

5532.1
3600
= /?x 1.6524 + = {Rx 1.6524 +2.4392) kg/s
37
1
100

This stream is leaving at 50oC.

Enthalpy balance around second section:
Enthalpy of solution leaving the second section - Enthalpy of recirculated stream
- Enthalpy of solution coming from 1st section. = Heat of solution x Formaldehyde
absorbed in 2nd section.
(1.6524 xR + 2.4392) CL (50 - 25) - 1.6524 R C[ x (40 - 25) - 1.6524 C[ x (40 - 25)

62.75x1000
-(2.4392- 1.6524) (I)
30

50 + 25
where, Q = 4.1868 I - 0.005 34 x 37 + (0.004 + 0.000 01x37)
2
CL = 4.0457 kJ/(kg • 0C) (H)

40 + 25
C/ =4.1868 1 - 0.005 34 x 37 + (0.004 + 0.000 01x37)

Ci = 3.9542 kJ/(kg • 0C) (III)

40 + 25
Q" =4.1868 1 - 0.005 34 x 7 + (0.004 + 0.000 01x7)

C[ = 4.5841 kJ/(kg • 0C) (IV)

From (I), (II), (111) and (IV)
(1.6524 xR + 2.4392) x 4.0457 (50 - 25) - 1.6524 R x 3.9542 (40 - 25) - 1.6524
x 4.5841 (40-25)

62.75x1000
= (2.4392 - 1.6524)
30
Process Engineering Channel

69.119 R - 133.085 = 1645.723

R = 25.7354
Amount of recirculated stream back to the top of second section = 25.7354 x 1.6524
= 42.525 kg/s
Second intercooler will cool this stream from 50oC to 40oC.
Heat duty of second intercooler,
@ProcessEng

02 = m Cl(50 - 40) = 42.525 x CL (50 - 40)

50 + 40
Q = 4.1868 1 - 0.005 34 x 37 + (0.004 + 0.000 01x37)
 Process Design of Absorbers 639 [

Q =4.1829 kJ/(kg • 0C)

(p2 = 1779 kW
Let cooling water enters to this cooler at 320C and leave at 370C. Mass flow rate of
cooling water required.

1779
mw = = 84.98 kg/s
4.1868 x (37-32)
Flow rate of cooling water required = 84.98 x 3600 = 305 928 kg/h = 306 m3/h.
It is planned to use the same stream of cooling water at 370C as a cooling medium for
both, top section inter cooler and inlet gas cooler on parallel basis. Let the outlet tem-
perature of cooling water from top section intercooler is equal to 390C.
0, = 161.27 kW= m, x 4.1868 x (39 - 37)
m, = 19.26 kg/s
Remaining, /hj = 84.98 - 19.26 = 65.72 kg/s will be used for the gas cooler.
Calculations for heat duty of gas cooler:
Reactor exist gas is at 110oC and at 135 kPa pressure. This gas mixture is cooled from
110oC to 550C in cooler.
(a) Dew point temperature calculation:
Mass % of water in Reactor exist gas = 6.42 %
Molar flow rate of reactor exit gas

40 6806.8 29626.8 2766 3341.3 386.6 27.7 4 9.9 45.5

— 1 1 1 1 1 1 1 1 1
32 32 28 18 30 44 28 2 16 46
= 1550.49 kmol/h
Moisture (HjO) content of gas mixture

2766/18
z/oo/io =0.11001- kmolfLO

1550.49- ( 2766 ) kmol of dry gas

I 18 J
At dew point

Pv
= 0.11001
P, - Pv
Process Engineering Channel

—^ =0.11001
135-A,
1.110 01 pv = 135 x 0.110 01 = 14.851 35
pv = 13.379 kPa
0
At 5L6 C temperature vapour pressure of water is 13.379 kPa. Hence, dew point tem-
perature of gas mixture is 5L60C. Therefore, on cooling the gas mixture from 110oC to
550C, no condensation is expected.
@ProcessEng

Heat duty of cooler,

(273.15+110)
h = 1 C»pldT
(273.15+55)
 Introduction to Process Engineering and Design

!/>,•( 383.152-328.152)
03 = la,-(383.15 - 328.15) + —^^

Z Cj (383.153 - 328.153) I ^ (383.154 - 328.154)

3 4
Zcz(, Z/?(, Zc( and Zc/, are taken from Ref. 10.

2267.1 xlO"3
03 = 47 588.5 (383.15 - 328.15) (383.152 - 328.152)

15 211.7 x 10-6 , , 5816.3xlO-9

+ (383.153 - 328.153) (383.154 - 328.154)

03 = 2617 367.5 - 44 346.20 + 106 035.4 - 14 476.6

03 = 2664 580.1 kJ/h = 740.16 kW
Total heat removed by two intereoolers and one gas cooler
= 0, + 02 + 03
= 161.27 + 1779 + 740.16 = 2680.4 kW
03 = m x 4.1868 (t0 - 37) = 740.16
65.72 x 4.1868 (t0 -31) = 740.16
t0 = 39.690C
Outlet temperature of cooling water from the gas cooler,
t0 = 39.690C
Calculations for number of trays required
(a) Top section:
Flow rate of fresh water at top, = 5532.1 kg/h
5532 1 307.34 kmol/h
=
18

x2 = 0, X2 = —= 0
1 —x2
Mass flow rate of exist gas at top = 39 556.3 kg/h
G2h. = 39 556.3 kg/h
Molar flow rate of gas mixture at the outlet of absorber,
Process Engineering Channel

^ 6806.8 29 626.8 2649 386.6 27.7 4 9.9 45.5

G-, = + + + + +—+—+
32 28 18 44 28 2 16 46
= 1431.36 kmol/h
Let concentration of formaldehyde in outgoing gas mixture = 120 ppm
y2 = 120 x 10-6 = 0.000 12
@ProcessEng

Y2 = —^ =0.000 12
l-}'2
Let Xj = Mole fraction of formaldehyde in solution entering to the second
section.
y2 = Mole fraction of formaldehyde in gas mixture leaving the second
section.
 Process Design of Absorbers 641

nF = Moles of formaldehyde in liquid solution entering to second section

42.525x0.37 + 1.6524x0.07
nF =
30
nF = 0.528 33 kmol/s
Moles of water in the same solution

42.525 (1 - 0.37) +1.6524 (1 - 0.07)

~ 18
nw = 1.5737 kmol/s

0.528 33
x.' = =0.251 34
" 0.528 33 + 1.5737

X 2 = —=0.335 72
1 — X2
Formaldehyde absorbed in top section
\
' 5532.1
-5532.1
1-0.07
GS(Y; - Y2):
30

Gs(Y2 - Y2) = 13.88 kmol/h

Gs = G2(l -y2) = 1431.19 kmoFh

1431.19 (y2 -0.000 12) = 13.88

y/ =0.009 818

y'
y2 = —^ = 0.009 72
■ - 1 + y2
At the base of tower
G, = 1550.49 kmol/h
Mole fraction of formaldehyde in gas mixture

3341.3
Process Engineering Channel

30
y, = =0.071 83
1550.49

y, = ^l— = 0.0774
i-y.
Flow rate of liquid solution leaving the tower
@ProcessEng

Llw = Rx\ .6524 x 3600 + 9030.4 (R = 25.7354)

Liw = 162 121 kg/h

(Note: From this stream 9030.4 kg/h is separated as the product stream and the remain-
ing is recirculated back)
 Introduction to Process Engineering and Design

Average molar mass of product solution

M = ^ =21.175 kg/mol
37 | 62.56 | 0.44
30 18 32
162121
L, = =7656.25 kmol/h
21.175
Mole fraction of formaldehyde in this solution.
162121 x 0.37 "l
30
x, = =0.261 16
1
7656.25

X, = = 0.353 47
l-x,
JC2' x 30
Mass % of formaldehyde at the top of second section = x 100
*2 x30 + (l-X2)xl8

0.25134x30x100
0.25134 x 30 + (1-0.25134) x 18

vvj = 35.878%

35.878 + 37
Average mass % of formaldehyde in second section = = 36.44 %

Average temperature of absorption = 450C

Partial pressure of formaldehyde in atmospheric air over formaldehyde solution is given
by Lacy's empirical equation. (Ref: 12).

Log pv = 9.942 - 0.953 (0.488)"'710 - 2905/7

At r = 45 + 273 = 318K and w = 36.44 %

pv = 5.46 torr
At atmospheric pressure,

.... . , , 5.46/760
equilibrium constant, m =
(36.44/30)/( 36.44/30 + (100 - 36.44)/18)
Process Engineering Channel

m = 0.028 at atmospheric pressure

Operating pressure in the given absorber is closed to atmospheric, hence the average
value of m for second section is 0.028.

Y X
= 0.028
1+Y I+X
Y 0 0.005 0.01 0.015 0.02 0.025 0.028
@ProcessEng

X 0 0.216 0.547 1.1177 2.336 6.76

Average mass % of formaldehyde for top section, w = -^ = 3.5 %

30 + 60
Average temperature of absorption = = 45 0C
 Process Design of Absorbers 643

3.5
log pv = 9.942 - 0.953 (0.488)JO
10
- 2905/7

pv = 1.1625 torr [for T = (273 + 45) K]

(1.1625/760)
m = = 0.071 82
(3.5/30)/([(3.5/30) + (96.5/18)]

Y X
= 0.071 82
1+Y \+X
Equilibrium data 1st section
Y 0 0.001 0.002 0.003 0.004 0.006 0.008 0.01
X 0 0.014 0.0286 0.0434 0.0587 0.09 0.1242 0.16

0.01

i
0.009

/
0.008

/
0.007
/
4i
0.006
/?/
47
/
0.005

0.004 /

y
/ fy
0.003 •CVc*
.P"
Process Engineering Channel

/
0.002 /

/
0.001
+•
@ProcessEng

/>

0.01 0.02 0.03 0.04 0.05 0.06

X

Fig. 9.16 Theoretical Stage Calculations for Top Section of Formaldehyde Absorber
 644 Introduction to Process Engineering and Design

0.08

0.07

0.06

0.05

0.04
o
c
bJ)
c
0.03
J—
<D
Cl.
o

0.02

0.01 .■ ■( —■ Pi
yj
e

0
0 0.1 0.2 0.3 0.4 0.5 0.6
X
Fig. 9.17 Theoretical Stage Calculations for Bottom Section of Formaldehyde Absorber

For 1st section operating line starts from (0, 0.000 12) to (X, 0.009 817).
7_
r 30
where X = —^ and x = ——— = 0.0432
l-x J_ + 21
Process Engineering Channel

30 18
X = 0.045 16
Number of theoretical stages required in top section is n, = 3.73
For 2nd section operating line starts from (0.335 72, 0.009 818) and terminates at
(0.353 47, 0.0774).
Number of theoretical stages required in bottom section is ^ < 1 but assumed as 1.
Total no. of theoretical stages required for the desired separation, nT = 4.7304
@ProcessEng

Tower diameter calculations

At the base of second section
Glw = 43 054.6 kg/h, Llw= 162 121 kg/h
Average molar mass of gas mixture that enters the tower,
43054.6 kg/h
M = = 27.768 kg/mol
1550.49 kmol/h
 Process Design of Absorbers 645

Liquid vapour flow factor Flv for sieve tray tower

F.„
i.v = (8.66)
G Pi.

Lw = LUv = 162 121 kg/h

GH, = G|H, = 43 054.6 kg/h

PMv 135x27.768
Pv = = 1.375 kg/m3
RT 8.3145 x (273+ 55)

1 1
Pl = 0.37 0.6256 0.0004
w, | |

815 988 780

Pu
(Density of water at 50oC pw = 988 kg/m3, pFo = 815 kg/m3, pme = 780 kg/m3)
pL = 919.37 kg/m3

162121 / L375
flv = = 0.1456
43 054.6 V 919.37
For tray spacing, S = 0.45 m
From Fig. 8.16 Cj= 0.069
Flooding velocity

>0.2 >0.5
o. Pl-Pv
vF - Cf (8.65)
0.02 Pv
oL = Surface tension of liquid, N/m
ctl = I a, x- = 0.26 (TFo + 0.74 C7wat

[^] for HCHO = 15.5 + 66 = 81.5

(Table 3-343 ofRef. 3)

pM 135 x 30
Pg = = 1.5 kg/m3
RT 8.3145 x (273+50)
Process Engineering Channel

(815 - 1.5) x 10 -3
< = 81.5 = 2.21
30

dyn
cjFo = 23.85 = 23.85 x lO-3 N/m
cm
,-33 N/m
ol = 0.26 x 23.85 x lO"3 + 0.74 x 70 x lO"3 = 58 x K)"
@ProcessEng

0.2 0.5
0.058 919.37-1.375
V/.- = 0.069
0.02 1.375
= 2.206 m/s
 Introduction to Process Engineering and Design

Let actual velocity of gas - vapour mixture through tower

V| = 0.66 vF = 1.456 m/s
Volumetric flow rate at bottom (of gas mixture)

G\w 43 054.6/3600 ,
qv, = = 8.7 m /s
pv 1.375
Net area of tray required at bottom

. Vvi 8.7 -7
A,, = = = 5.975 nr
v 1.456
Let downcomer area, = 0.12
where
A(, = Inside cross sectional area of tower
A„ = Ac - Ad = Ac - 0.12 Ac = 0.88 Ac
0.88 Ac = 5.975 m2

Ac = 6.79 m2 = f^l^2

D, = 2.94 m
Tower diameter required at the base of top section:
At the base of top section.
Lw = 1.6524 kg/s
Gas flow rate at the base of 1st section
Gw = Gas flow rate at top of 1 st section + Lw - Solvent flow rate at top
Gw = 39 556.3 + 1.6524 x 3600 - 5532.1
CH, = 39 972.84 kg/h = 11.1036 kg/s
Molar flow rate of gas mixture at the entrance of 1st section,

G = Gs (1 + T2') = 1431.36 (1 + 0.009 818)

G = 1445.41 kmol/h

39972.84
M,,.. = = 27.655 kg/kmol
S
1445.41

pMav 135x27.655 ,
Process Engineering Channel

Pv = 135 k8/m
~ RT 8.3145 x(60 +273) ~

"-^0.07 '0.93 ~ 969.2 kg/m3

pLj 815 983.2

(Density of water at 60oC = 983.2 kg/m3)

@ProcessEng

f
lv = ^^- = 1^^=5.554x10-3
Glv V pL 11.1036 V 969.2

for tray spacing S = 0.45 m

from Fig. 8.16 Cy= 0.08
 Process Design of Absorbers

Surface tension of 7 % formaldehyde solution.

= t-OPi = Op^ + (1 - x) (7wal

7/30
x= = 0.0432
7/30 + 93/18
oL = 0.0432 x 23.843 x lO"3 + (1 - 0.0432) x 70 x lO"3
oL = 0.(
Ol 0.068 N/m
Flooding Velocity

/ \ 0.2 / \ 0.5
Gl ' Pl-Pv
v
f - Cp
10.02 J K Pv )

0.2 0.5
0.068 969.2-1.35
= 0.08 = 2.736 m/s
0.02 1.35
For 66% flooding,
v = 0.66 x 2.736 = 1.8 m/s
Volumetric flow rate of gas mixture at the base of 1st section.

11.1036 g T.,
qv = = 8.225 m /s
^ 1.35
Net area of tray required,

Qv 8.225
= 4.57 m2
v 1.8
Let downcomer area = 12 % of column area (Ac)

A = = 5.19 m2 = -D}
0.88 4 '

4x5.19
D: = = 2.57 m
TT
Checking of weeping for bottom section:
The minimum design vapour velocity through holes to avoid weeping is given by
following equation.
Process Engineering Channel

-0.9(25.4-4)
uh = (8.70)
yfpa
uh = Minimum gas velocity through holes, m/s
K = Constant can be obtained from Fig. 8.19
dh = hole diameter, mm
Let dh = 5 mm, pG = 1.375 kg/m3
@ProcessEng

Height of weir, hw = 50 mm
Height of liquid crest over the weir

L..
how = 750 (8.69)
PlK
 648 Introduction to Process Engineering and Design

Lw = Liquid flow rate, kg/s

Lw = 162 121 kg/h = 45.03 kg/s
pL = Density of liquid = 919.37 kg/m
lw = Length of weir, m

For = 0.12 = 0.76

Ar D:
I. = 0.76x2.94 m = 2.2344 m
2/3
45.03
K.w = 750 = 58.7 mm
919.37x2.2344

hw + how = 108.7 mm, A" = 31.2

31.2-0.9(25.4-5)
Ui, =
V 1.375
uh = 10.95 m/s,
Maximum hole area required

A, = = 0.7945 m2
" 10.95

A hm 0.7945
= 0.117
6.79

Let Ay, = 0.08 Ac= 0.5432 m2

Actual velocity, of gas through holes, Vw = 16 m/s > 10.95 m/s
Hence, weeping will not take place.
Checking of weeping for top section:
For the trays of top section, let hole diameter, dh = 5 mm
Height of weir, hw = 50 mm
Height of liquid crest over the weir
2/3
A,
h = 750 (8.69)
p/A-
Process Engineering Channel

Lw = Liquid flow rate = 1.6524 kg/s

pL = 969.2 kg/m3

A. L_
For = 0.12 = 0.76
A, D:
Length of weir,
/ =0.76x2.57= 1.9532 m
@ProcessEng

2/3
1.6524
Kw = 750
969.2x1.9532

how = 6.85 mm
for hw + how = 56.85 mm, K = 30.2
 Process Design of Absorbers

Minimum vapour velocity required through holes to aviod weeping

K - 0.9 (25.4 - dh)

uh = (8.70)
VPc

30.2-0.9(25.4-5)
u
h =
yflJE
uh = 10.19 m/s under weeping conditions
Maximum hole area which can be provided,

. 8.225 n t
Ahm = = 0.8072 m
10.19

Ahm 0.8072 m2
= 0.1556
—(2.57 y
4

A
h
Let — = 0.1
^C-
Ah = 0.1AC = 0.518 75 m2
Actual velocity of gas through holes,
8 225
= - = 15.855 m/s > 10.10 m/s
0.518 75
Hence weeping will not take place.
Checking of downcower flooding for the bottom section:
Clear liquid back-up in downcomer,
hb=hw + hoW + h, + hdc (8.81)
where, h, = Total tray pressure drop, mm LC
hlC = head loss in downcomer, mm LC
h, = hd + (hw + how) + hr (8.73)
where, hd = Dry tray pressure drop, mm LC
hr = Residual pressure drop, mm LC
Process Engineering Channel

/ N2
V/, Pr
h., = 51 — (8.74)
PL
where, C0 = Orifice coefficient can be determined by using Fig. 8.20
Let plate thickness = 5 mm,

Plate thickness 5 ^
@ProcessEng

hole diameter 5

A
h A,, Ah Ah
A,, Aa Ac - 2 A(l A(. - 2 x 0.12 Ac
 Introduction to Process Engineering and Design

A,. Ah = ().Q8
= 0.1053
0.76 /i,. ~ 0.76

C0 = 0.845 (From Fig. (8.20))

\2
15.67 1,375
hd = 51 x x = 26.23 mm LC
0.845 919.37
Residual pressure drop,

12.5 xlO3 12.5 xlO3

h.. = = 13.6 mm LC
Pl 919.37
h, = 26.23 + (50 + 58.9) + 13.6 = 148.73 mm
/?,. = 50 + 58.9 + 148.73 + hdc
head loss in downeomer,

hdc = 166 (8.78)

Pi. K
Lwd = Liquid flow rate in downeomer, kg/s
Am = Ad or Aap whichever is smaller
4 —hi
™ap "aplw
hap = Clearance between bottom edge of downeomer apron and tray

Kp =hw-{5\.o 10 mm)

45.03
hdc = 166
919.37 x A m /

Am = Ad (0.47 m2) or Aap (0.04 x 2.2344 = 0.089 38 m2)

A„. = 0.089 38 m2

45.03
hdc = 166
919.37x0.089 38

^dc = 49.85 mm
hb = 50 + 58.9 + 148.73 + 49.85
hb = 307.48 mm
Process Engineering Channel

S + hw = 450 mm + 50 mm = 500 mm
hb > 0.5 (S + /7h,)
Hence, downeomer flooding will take place. To avoid flooding, let tray spacing in
bottom section, S = 600 mm
For FIV = 0.1456
CF = 0.09 (From Fig. (8.16))
@ProcessEng

0.09
Flooding velocity, vF = x 2.206
0.069
vF = 2.877 m/s
v, = 0.66 vF= 1.9 m/s

A= — = 4.579 m2
" 1.9
 Process Design of Absorbers

A.. = = 5.2034 nr
0.88
D, = 2.574 m (Nearly same as top section)
Length of weir, lw = 0.76 x 2.574 = 1.956 m

45 03 f/3
h. = 750
^ 919.37x1.956 j
=
Kw 64-2 rnm
hw + how = 50 + 64.2 = 114.2 mm
K = 3\.2 (from Fig. 8.19)
Minimim vapour velocity required through holes,

31.2-0.9(25.4-5)
uh = —
yj 1.375
uh = 10.95 m/s

Let = 0.1
A.

^ =0.1 x ^ (2.574)2 = 0.52 m2

Actual gas velocity through holes

8.7
= 16.73 m/s > a,, = 10.95 m/s
0.52
Hence, weeping will not take place.
Checking of downcomer flooding:
Dry plate pressure drop,
/ \2
D, Pg
h,,= 51 (8.74)
Pl

Plate thickness . 5
hole diameter " 5

A, Al
Process Engineering Channel

0.1
= 0.1315
Ap 0.16 Ac 0.76

Cn = 0.87 (From Fig. (8.20))

/ = 51
h,, ci w
x i 16.73 f x
^ 1.375 = 28.2
, mm LC
Tn
0.87 ) 919.37
h, = 28.2 + 50 + 64.2 +13.6=156 mm
@ProcessEng

hh = 50 + 64.2 + 156 + hdc

Am = Aap = 0.04 x 1.956 = 0.078 24 m2

45.03
hdc = 166
919.37x0.078 24
 Introduction to Process Engineering and Design

hdc = 65 mm LC
hb = 50 + 64.2 + 156 + 65 = 335.2 mm LC
5 + hw = 600 + 50 = 650 mm
^4: 0.5 (5 + hw)
Let hap = hap - 5 mm = 45 mm
Am = Aap = 0.045 x 1.956 = 0.088 m2
hdc = 51.4 mm
hb = 321.6 mm < 0.5 (600 + 50)
Downcomer flooding will not take place.
Downcomer residence time,

AAPl
e =
Luwd
,.

(0.12x5.2034) xO.3216 X919.37

e =
45.03
9r = 4.1 sec > 3 s (satisfactory)
Checking of downcomer flooding in top section
Dry plate pressure drop.

v
h Pg
hd=5\ (8.74)
yCo; Pl

Plate thickness
= 5 =1
Hole diameter 5

Ah 0.1
= 0.1315
0.76 A,. 0.76

C0 = 0.87 (From Fig. 8.20)

15.855 1.35
h,i = 51 = 23.6 mm
0.87 969.2
Residual pressure drop,
Process Engineering Channel

12.5 x 103 12.5 x 103

h= = 12.9 mm
pL 969.2
h, = 23.6 + 50 + 6.85 + 12.9 = 93.35 mm
lw = 1.9532 m, Aap = 0.045 x 1.9532 = 0.088 m2
Head loss in down comer,
@ProcessEng

n2
" L .j
hdc =166
Pl Am

1.6524
= 166
969.2x0.088
 Process Design of Absorbers 653

hdc = 0.0623 mm
hb = 50 + 6.85 + 93.35 + 0.06 mm = 150.26 mm
5 + hw = 450 + 50 = 500 mm
hb < 0.5 (5 + hM)
Downcomer flooding will not take place.
Downcomer residence time

0.121 - l2.57z x 0.15x969.2

Ad hb p, V4
H. =
Lwd 1.6524

0,. = 54.77 s (satisfactory)

Tray efficiency:
Overall tray efficiency based on O'Connell correlation for the absorption in tray tower
is given in Fig. 14.7, Perry's Chemical Engineers' Handbook, 7thEd., 1998.
The O'Connell parameter for top section

PL 969.2
KMpL KMpL

where, K = Equilibrium constant

M = Average molar mass of liquid solution
pL = Viscosity of liquid solution
For top section:
K = 0.071 82

Q 0432
M= - x 30 + fl - M432 1 x 18 = i8.26
')
p = Viscosity of liquid solution = 10-3 Pa ■ s

Pl 969.2
= 739 038.8 kmol/(m • Pa • s)
KM pL 0.07182 x 18.26 xlO-3

739 038.8
= 46.2 lb mole /(ft3 • cP)
4
1.6 xlO
Process Engineering Channel

Plate efficiency, rj is more than 60% (from Fig. 14.7, Perry's Chemical Engineers Hand-
book, 7th Ed.)
For bottom section:

Pi 919 37
= 1298 288.2 kmol/(m3 ■ Pa ■ s)
KM pL 0.028 x 21.0756 x 1.2 xlO-3

(M = 0.2563 x 30 + (1 - 0.2563) x 18 = 21.07563)

@ProcessEng

= 81.143 (lb mole/(ft3 • cP)

Plate efficiency, rj is more than 60%
(From Fig. 14.7, Perry's Chemical Engineers Handbook, 7th Ed.)
However, plate efficiencies of commercial hydrocarbon absorbers are ranging from
15 to 55%.
 Introduction to Process Engineering and Design

Let tray efficiencies be 0.34 for top section and 0.33 for bottom section
Hence, actual number of sieve trays in top section will be 11 and in bottom section
will be 3. Total numbers of sieve trays required is 14.
Resulting data:
Inside diameter of tower = 2574 mm
No. of trays in top section =11
No. of trays in bottom section = 3
Flow rate of liquid (37% formaldehyde) solution recirculated and fed to the top of bot-
tom section = 153 239 kg/h
Figure 4.7 is the P&I diagram of the entire formaldehyde manufacturing. It may be
noted that entire cooling water is first supplied to HE-3 which has highest heat duty
(1779 kW). Cooling water, leaving HE-3, is split into three streams. One stream is sent
to HE-4. (746.32 kW), another to HE-2 (161.27 kW) and a small stream to sample
cooler SC-I. This will mean a cooling range of for the cooling water flow rate of 306.0
m3/h. Thus cooling water enters at 320C and leaves the plant at 39.550C. In an alternate
design, fresh cooling water could be supplied at 320C to all the coolers separately and
each cooler could be designed for a temperature rise to 370C. This will mean a cooling
range of 50C for cooling water flow of 462.0 m3/h for the design of cooling tower.
In cooling tower design wet bulb temperature is an important consideration. Cold
water temperature is limited by approach to the wet bulb temperature. Cooling tower
with a range of 7.550C and flow rate 306 m?/h will require lesser floor space than the
cooling tower with a range of 50C and flow rate of 462.0 m3/h. Hence, cost of cooling
tower with a cooling range of 7.550C will be lower. Also, cost of pumping cooling water
will be lower.
Above discussion should not mislead to assume that coolers should always be de-
signed for series cooling as heat transfer area requirement of the coolers also will have
to be checked vis-a-vis cooling tower design. In general, a cooling range of 10 to 120C
and approach of 50C to wet bulb temperature of air can be considered optimal for the
design of cooling water system.

Exercises

9.1 Design a scrubber for absorbing dimethyl ether (DME) vapour from nitrogen-dime-
thyl ether vapour mixture. The temperature in the scrubber is 20oC and scrubbing is
Process Engineering Channel

approximated as isothermal. Operating pressure of scrubber is atmospheric. A mix-

ture of nitrogen - DME vapour contains 10% DME (by volume) and its flow rate is
60 kmol/h. The scrubber is required to absorb 98% of the DME. Molar mass of
DME is 46 kg/kmol. Cold water is used as solvent.
9.2 Gas mixture obtained from chlorination process contains 20% hydrogen chloride
gas and 80% chlorine (by mole). From the mixture, hydrogen chloride gas is to be
@ProcessEng

separated by absorption in water. For the absorption of HC1, FRP (fiber glass rein-
forced plastic) packed tower is used. Product hydrochloric acid solution, leaving
the packed tower, must contain 30% HC1 (by mass). Design the FRP packed tower.
9.3 Falling film absorber is used in ammonia-water absorption refrigeration plant10.
Refrigeration duty of this plant is 200 kW (56.87 TR). Flow rate of ammonia
vapour, entering to falling film absorber is 0.1935 kg/s. It is absorbed by weak
aqueous solution of ammonia having 30% strength (by mass). Product strong
solution of ammonia leaving from the bottom of absorber is having 36.5% strength.
 Process Design of Absorbers

Average value of heat of absorption of ammonia for the required concentration

change is 2046.6 kJ/kg. Design the falling film absorber. Temperature of ammonia
gas at inlet to absorber is -1()0C.
Operating pressure = 280 kPa a
Assume that Eq. (9.43) and Eq. (9.44) are also valid for the absorption of ammonia
in water (in falling film absorption) to calculate mass transfer coefficient and heat
transfer coefficient, respectively.
9.4 Venturi scrubber is planned for absorbing NOx gases from the exist gas stream of
nitric acid plant by using 10% NaOH solution (by mass). Exist gas mixture, leaving
the absorber of nitric acid plant, is having the following composition (Ref.: Table
2.7 of Chapter 2).
Component kmol/h
N. 1275.097
Cf 61.590
Ar 16.330
NO 2.790
N20 2.190
ffO 173.805
Total 1531.802
Discharge pressure of gas from venturi = atmospheric, solvent to gas ratio = 1.5 L/
m3.
Temperature of gas mixture, entering the venturi scrubber = 50oC.
Determine: (a) throat diameter of venturi scrubber,
(b) % removal of NOx gases,
(c) consumption of NaOH and
(d) pressure drop in venturi scrubber.
9.5 Design a sour-water stripper based on following information.13
Feed liquid mixture flow rate = 50 000 kg/h
% of H2S in feed = 0.73% (by mass)
% of NH3 in feed = 0.556% (by mass)
% of H26 in feed = 98.714% (by mass)
Feed condition = Saturated liquid at operating condition
Stripping steam rate = 5100 kg/h
Operating pressure at bottom = 2.4 atm a
Concentration of H2S and NH3 in bottom stream = 5 ppm and 20 ppm, respectively
Operating temperature at bottom = 1260C
Steam is generated by using reboiler at bottom. Stripped overheads are to be
Process Engineering Channel

condensed in overhead condenser. Condensate and tail gas from this condenser are
separated in reflux drum. Liquid phase from drum is recycled back to top tray. Tail
gas will be sent to sulphur recovery plant.
9.6 From a 10 mole% NH3 in N^-air mixture, 95% of the ammonia is to be removed
by countercurrent scrubbing at I atm and 20oC. Entering gas rate is 3600 kg/(h •
m2). Calculate the followings for both solvents, water and 0.1 N H2S04 solution.
For NHj-HjO system Henery's law constant at 30oC, m = 0.85 (Ref: 1).
@ProcessEng

(a) Minimum amount of solvent

(b) Number of theoretical stages at 1.2 times the minimum acid rate.
(c) The number of overall gas transfer units, Nqq
(d) Hog based on KGa14.
KGa = 78.1 kmol/(h • m2 • atm) for 0.1 N H2S04 solution
KqU = 0.481 kmol/(h • nr • atm) for water
(e) Column height
 Introduction to Process Engineering and Design

References

1. Treybal, R. E., Mass Transfer Operations, 3rd Ed., McGraw-Hill, 1980

2. Ludwig, E. E., Applied Process Design for Chemical and Petrochemical Plants,
3rd Ed. Vol. 2, Gulf Publishing Co., USA, 1997.
3. Perry, R. H. and Green D., Perry's Chemical Engineers' Handbook, McGraw-Hill,
6th edition 1984, Ch - 14 and Ch - 18.
4. Sinnott, R. K., Coulson and Richardson's Chemical Engineering, Vol. 6, Revised
2nd Ed., Asian Books Private Limited, New Delhi, 1988.
5. Timmermans, J., Physico-Chemical Constants of Pure Organic Compounds, Elsvier
Publishing Co., USA, 1950.
6. Edwards, W. M. and P. Huang, Chem. Engg. Progr, 73(8), (1977) p. 64.
7. Niessen. W. R.. Comhusion and Incineration Processes, 3rd Ed., Marcel Dekker,
Inc., USA, 2002.
8. Norman, W. S., Absorption, Distillation and Cooling Towers, Longmans, USA,
1961
9. Kister, H. Z., G. Balekjian, J. F. Litchfield, J. P. Damm and D. R. Merchant, Chem.
Engg. Progr., 88(6), (1992) p. 41.
10. Bhatt, B. I. and S. M. Vora, Stoichiometry, 4th Ed., Tata McGraw-Hill Publishing
Company Limited., 2004.
11. Kern. D. Q., Process Heat Transfer, McGraw-Hill, 1950.
12. Mcketta, J. J. and W. A. Cunningham (Ed.). Encyclopedia of Chemical Processing
and Design, Marcel Dekker INC., Vol. 23, 1985, p. 353.
13. Wild, N. H., Chem. Engg., 86(4), Feb. 12, 1979, p. 103 to 113.
14. Henley, E. J. and J. D. Seader, Equilibrium-stage Separation Operations in Chemi-
cal Engineering, John Wiley & Sons, USA, 1981.
15. Sherwood, T. K., Pigford, R.L. and Wilke, C.R., Mass Transfer, McGraw-Hill, 1975
Process Engineering Channel
@ProcessEng
 Chapter
10

Process Design of

Reactors

10.1 INTRODUCTION

Reactor is the most important equipment of any chemical plant. Minor change or
improvement in the reactor design or in its performance greatly affects the process
and mechanical design of other equipments. Sometimes it may even change the
entire flow sheet. For example, in the process of manufacturing of monochloro-
acetic acid, reaction is carried out between acetic acid and chlorine. Conversion
of acetic acid is about 90%. Product mass contains a mixture of monochloroacetic
acid, dichloroacetic acid and unconverted acetic acid from which monochloro-
acetic acid is separated by crystallization. But, if in the same reactor, conversion
of acetic acid is restricted to 50%, then dichloroacetic acid is not formed in
noticeable quantity and the product mixture contains mainly acetic acid and
monochloroacetic acid from which monochloroacetic acid can be separated by
vacuum distillation. Thus, change in conversion of reactant in the reactor changes
the entire flow sheet. Hence, for any chemical process, development in the reaction
kinetics or reactor design is important in research. Major area of the research is
the development of catalyst for the reaction. By developing a new catalyst, entirely
a new process route can be developed. Final goal of the research for all the reactions
and reactors is to carry out the reaction at atmospheric pressure and at room
temperature with sufficiently high rate of reaction, 100% conversion and 100%
Process Engineering Channel

yield. At the same time heating or cooling medium requirement to run the reaction
should be minimum. To achieve this goal one can take inspiration from natural
reactor like human body. In the human body thousands of reactions are running
at about 370C temperature and at a pressure close to one atmosphere. For the
process design of the reactor, knowledge of various subjects of chemical
engineering is required like of chemical reaction engineering, thermodynamics,
stoichiometry, heat transfer operation, mass transfer operation, fluid flow operation,
@ProcessEng

chemistry, etc. Process design of various types of reactors are outlined in the
subsequent sections.

10.2 DIFFERENT TYPES OF REACTORS

Several types of reactors are in use in industry. Basically they fall in two categories;
batch and continuous. In each category, different designs are available. In fact,
 Introduction to Process Engineering and Design

development of a reactor can be an innovative idea and a process engineer can

use his skills for such a development.
In Fig. 10.1, different types of reactors are represented schematically. Designs
date back to a simple batch reactor to modem continuous catalytic reactors such
as ammonia converter. Designs also vary with the type of reactions; such as
homogenous, heterogeneous, run-away reactions, etc.
In many cases, a number of reactors are used in series. Continuous stirred tank
reactors. [Fig. 10.1(c)] can be cited as an example. In some cases, number of
parallel reactors are used. For example, in reforming of hydrocarbons (such as
naphtha or natural gas), several hundred tubular reactors are used in parallel in
which catalyst is packed in different shapes and sizes. Selection is made on the
basis of degree of conversion, ease of heat removal/addition, safety and other
considerations.

10.3 BATCH REACTOR1 •2 3

In a batch reactor all the reactants are initially charged into the reactor. In most
cases, then they are allowed to react for certain period of time. The resultant
mixture is then discharged. In any batch reactor, composition of reaction mass
changes with lime, hence it is called unsteady state reactor.
In an ideal batch reactor at any instant, composition throughout the reactor is
uniform while the same is not true for a non-ideal batch reactor. Size of batch
reactor does not directly depend on the reaction time but it depends on volume of
material charged to the reactor. For small capacity plant having production ca-
pacity less than 5 tonnes per day, batch process with a batch reactor is more
economical than continuous process (continuous reactor).
In a batch reactor, variety of agitators are used. Each one has its specific ad-
vantages and limitations. Figure 10.2 gives different types of mixing equipment,
used in chemical industry. Selection of an agitator plays an important role in
achieving desired conversion in the reactors. In majority of reactors, turbine type
agitators are used. While for simple mixing, flat blade turbine agitator is used,
pitched blade turbine agitator is preferred for a slurry. For viscous liquids (such
as manufacture of amino/alkyl resins), anchor/paddle type agitators of different
designs are used. For homogenizing applications, such as milk powder dissolu-
tion in water, degumming of edible oils (with phosphoric acid), etc., shear mixer
is an ideal choice but is a costly equipment. For gas-liquid reactions gas induc-
Process Engineering Channel

tion type agitator and jet loop reactor are preferred. Design of agitation equip-
ment is discussed at length in literature. Reference (3) gives a good treatise on
the subject.

10.3.1 Industrial Examples of Batch Reactor

(a) Synthesis of dyes: Sulfonation of napthalene gives /3-sulfonale

(b) Benzene sulfonic acid from benzene
@ProcessEng

(c) Nitrobenzene from benzene with mixed acid

(d) Synthesis of polyurethan from toluene diisocyanate and polyglycol
(e) Synthesis of cypermathrin
(f) Batch fermenter: Fermentation of molasses to ethanol
(g) Manufacture of active pharmaceutical ingradients (API)
(h) Manufacture of amino and alkyd resins, etc.
 Process Design of Reactors

Gas In Rcactant
M TI
PI

Heater or
Cooler
Jacket Reactants
&
Products

Agitator
Sparger

(a) Batch Reactor (b) Typical Batch Loop Reactor

Feed Feed Feed

Feed

c o

c o

oo

Heating or Cooling Product

(c) Battery of Stirred Tank Reactors

Outlet
Outlet
Process Engineering Channel

Heating Coil
Outlet
Catalyst
OOOI CCO OOQ OCO OOO Solution

Heating coil
OOO QOO CQO QQD QQO OOC
@ProcessEng

OOO OOO OOO C-

OOO COO/ COO coo
Reactant Inlet Heating Coil
Connections Inlet

Inlet Inlet

(d) Longitudinal Tubular Reactor (e) Heterogeneous Continuous Reactor

Fig. 10.1 (Contd.)
 Introduction to Process Engineering and Design

Inlet

Outlet Heating/Cooling'
Tubes may be added for heating Medium Outlet
or cooling purposes
Solid Catalyst
. in Tubes

Heating/
Cooling
Inlet Medium
Inlet
(f) Baffle Tank Reactor
Outlet
(g) Longitudinal Catalytic Fixed Bed Reactor
Flue
Gas
Prodcuct

Regenerator
Reactor

Naphtha and
Recycle Gas

^ Steam
Shot and ^ Catalyst
Catalyst Shot -Fuel
Compressed—>- urnace
Air
(h) Fluid-Bed Catalytic Reactor

Catalyst Dosing
Liquid
Device
Process Engineering Channel

Gas In
-Jet Mixer
Out Impact Zone -^►Outlet

Heating/Cooling
Heating Medium
Medium
@ProcessEng

Jacket <—Inlet

(i) Jet Reactor

Fig. 10.1 (Contd.)
 Process Design of Reactors 661

Hydrogen Gas
Recirculation Line

Fresh
Hydrogen 1 Monolith
Gas Supply jj I Catalyst
Bed

CSTR
ok) Jacket
Typical Croos-section of
Monolith Catalyst
Recirculation
(100 parallel channels per sq. in)
Pump

(j) Monolith Loop Reactor

Fig. 10.1 Different Types of Reactors

(v) Flat Blade Disc

(i) Propeller Turbine Mixer (ix) Impeller (Pfaudler)

(ii) Straight Blade Turbine (vi) Concave Blade Disc Turbine (x) Toothed Disc
Mixer
Process Engineering Channel

(vii) Pitch Blade High Efficiency

(iii) Narrow Blade Turbine Impeller (xi) Anchor agitator
@ProcessEng

(iv) Pitch Blade Turbine (viii) Wide Blade High Efficiency (xii) Paddle Agitator
Impeller

Fig. 10.2 (Contd.)

 662 Introduction to Process Engineering and Design

c o
c
=®=
c
(xiii) Gate Type Anchor (xv) Flat blade agitator
(xvii) Grid

1 ki

1 K

(xiv) Cross beam (xvi) Helical ribbon impeller (xviii) Blade

(^Of Tank
Raw Oil ^Of Shear Mixer
Jo o oo o

9
3

q P

Recycling

—>- Outlet
Process Engineering Channel
@ProcessEng

(xix) Shear Mixing Unit

Fig. 10.2 Different Types of Agitators

 Process Design of Reactors

10.3.2 Advantages of Batch Reactors Over Continuous

Flow Reactors

(a) For small scale production, batch process with a batch reactor is more eco-
nomical than continuous process with continuous reactor.
(b) Batch reactors provide more flexibility. For example, it is readily possible
to increase the reaction time in the batch reactor while the same is difficult
in continuous flow reactor without sacrificing the production rate.
(c) Some process steps (upstream or downstream processing) of the reaction
can also be performed in the reactor.
(d) Batch reactors require less and relatively simple or cheaper instruments
while continuous flow reactors require more sophisticated and costlier in-
struments.

10.3.3 Disadvantages of Batch Reactors Over Continuous

Flow Reactors

(a) High manpower requirement

(b) Time is wasted in between two batches
(c) Temperature control is poor, especially for highly endothermic or exothermic
reaction. While starting reaction in a batch reactor, rate of reaction is high
and hence heat duty is substantially high.
Some of these aspects were discussed in Chapter 3.
(d) Quality of the product may vary from a batch to batch.

XA
; Ma
Performance equation of ideal batch reactor is 0 = NAo J (10.1)
o (~rA ) ^
where, 6 = Time required to achieve the conversion XA, s
XA = Fractional conversion of limiting reaclant A
-rA = Rate of reaction kmol/(m3 • s)
V = Working volume of reactor, m3
For the constant volume reaction system,
x x
Na f dXA * dXA
Process Engineering Channel

=
&- J — Cfa J — (10.2)
^ o -rA o "'A
where, CAo = Initial concentration of limiting reactanM.

Example 10.1
Butyl acetate formation is carried out in a batch reactor at 90oC with sulphuric acid as a
homogeneous catalyst. The feed contained 4.97 moles of n-butanol per mole of acetic
@ProcessEng

acid and the catalyst concentration is 0.032% by mass as H2SO4.

Rate equation for this reaction is - = kC\ ■
where, CA = Concentration of acetic acid in mol/cm3
k= 17.4 cm3/(mol. min) (Ref. 4)
Density of the reaction mixture at 90oC can be assumed constant and equal to 0.75
g/cm3.
 Introduction to Process Engineering and Design

(a) Calculate the time required to obtain conversion of 50%.

(b) Determine the size of reactor and the mass of reactants that must be charged to the
reactor in order to produce ester at the average rate of 100 kg/h. Conversion is 50%.
Reactor will be shut down for 30 min between batches for removal of product,
cleaning and start-up. Assume that batch reactor is ideal. Also decide height and
diameter of the reactor.
(c) Determine the heat duty required and heat transfer area required for starting condi-
tions of the reaction.
Solution:
(a) For ideal batch reactor, time required to obtain the conversion XA

clX x.
9= NAo J (10.1)
„ i-^v
Given reaction is a liquid phase reaction in homogenous phase hence working vol-
ume can be assumed constant.

N dX dXA
AO 7 A
9= = C Ao
J
V
o kC2A 0 kC2A0(l-XA)2

0.5
1 ( ! 1 )
9=
kC Ao 1-A, kC
Ao ^(1 - 0.5) (1-0)J

9= 1 1
(2-1)=
kC Ao kC*Ao

Moles of acetic acid

Qo -
Total volume

Moles of acetic acid Total moles

x
Total moles Total volume

-7 XPn
Cao =
Process Engineering Channel

(1/5.97)
Qo - x 0.75 = 0.0018 mol/cm3
1
x6()Uf^-x74
5.97 5.97

1 mole of acetic acid

Mole ratio in feed =
@ProcessEng

4.97 mole of butyl alcohol

xX = 1/5.97

1
M =, x60l+f^-x74 I =71.655
', 5.97 J \ 5.97
where molar mass of acetic acid = 60
 Process Design of Reactors 665

and molar mass of butyl alcohol = 74

k = 17.4 cmV(mol • min)

0= = 32 min or 0.53 h
17.4 x 0.0018
Time required to obtain 50% conversion is 32 min.

Mass of liquid (raw material) charged

(b) Working volume of reactor = ——;
Density of liquid mixture charged

Assume that volume of liquid mass inside the reactor will remain same during
the reaction (or change in liquid volume during the reaction in negligible).
For 100 kg/h ester production with 50% conversion,
Mass of acetic acid required per hour

_ 100 kg/h ^ molar mass of acetic acid

molar mass of ester 0.5

100 60 inQ ... „

= x — = 103.45 kg/h
116 0.5
(Molar mass of butyl acetate (CH^COCXTtHg) = 6x 12 + 2x 16 + 1 x 12 = 116)
Mass of acetic acid required per batch

(32 + 30)
mA = 103.45 x (Time between batches = 30 min)
^ 60
= 106.9 kg/batch
Reaction:
CHjCOOH,/, + C4H9OH(/) ^ CHjCOOC^y,/, + H20(/)
Reaction is carried out at 90oC and with 50% conversion.
Mass of butanol required per batch,

mg = x 74 x 4.97 = 655.26 kg/batch

Mass of H2SO4 required per batch

106.9 + 655.26
mt = x 0.000 32 = 0.244 kg/batch
Process Engineering Channel

' (1-0.000 32)

Total mass of raw materials = 762.4 kg

t/ 762.4 . n.,. ^
workins =
working 0_75 x (000 =1.01 65 ITT

Let — = 1,
@ProcessEng

D
i
where, h = Depth of liquid in reactor shell, m
Di = Diameter of vessel (Inside diameter), m
Let the type of bottom head = Torispherical
 Introduction to Process Engineering and Design

Inside volume of Torispherieal head,

V = 0.084 672 Df + ~ D,2 SF (Ref. 2) (10.3)

where, D, = Inside diameter of reactor, m

V = Inside volume, m3
Sh- = Straight flange, m

forking = j Dfh + 0.084 672 Df + ^ DfSF = 1.0165 m3

Let SF = 1.5 in = 0.0381 m and — = 1

D
i

1.0165 = ^£>3 + 0.084 672 D3 + 0.029 92 x D2

1.0165 = 0.870 007 D3 + 0.029 92 D2

D, = 1.042 m
h = height of liquid in shell = 1.042 m
Conside provision of 20% extra space for vapour-liquid disengagement, then
actual height of shell of reactor H = 1.2 m.
(c) To determine heat duty required at starting condition of reactor, heat of reaction
/SHr is required.

Table 10.1 Standard Heat of Formation and Heat Capacity Data

Compound AH/, kJ/mol at 250C Cu, kJ/(kmol ■ 0C) at 57.50C

Acetic acid -484.2 129.67

Butanol -327.3 215.41
Water -285.83 75.36
Butyl acetate -522.766 267.12

AHr = (-522.766 - 285.83) - (-327.3 - 484.2)

= 2.904 kJ/mol (at 250C) (endothermic)
In reactor, when reaction starts both reactants and products are at the reaction temperature
Heat of reaction at reaction temperature (90oC)
AHr = AHl + (Iv, CLi AO/1000
Process Engineering Channel

where, v,- = Stoichiometric coefficient = 1 for all reactants

Assuming heat capacities to be nearly constant up to 90oC,
(90-25)
AHr = 2.904 + (267.12 + 75.26 - 215.41 - 129.67) x
1000
AHr = 2.904 - 0.1755 = 2.7285 kJ/mol
Heat required at the starting of reaction
@ProcessEng

0 = A//s x 1000 x kmol/h of acetic acid consumed

+ Heat required to remove the water continuously from the reaction mass
of ternary azeotrope

- dN.
0= 2.7285x1000 x +t x 1.05 (Considering 5% heat loss)
clt
 Process Design of Reactors 667 |

Water will leave the reaction mass either as binary azeotrope with butanol (normal
boiling point = 92.20C) or as ternary azeotrope with butyl acetate and butanol (normal
boiling point = 89.40C). Boiling point of ternary azeotrope is less than binary azeotrope.
Composition of ternary azeotrope:
60.86% butyl acetate, 10.47% butanol, 28.92% water (by mass).

Butyl acetate formed j 16 6o.86 , . .,

Ratio of = = 6.44 > (= 2.1)
Water formed 18 28.92
Hence it will be logical to assume that water will leave as ternary azeotrope.
Rate of reaction at the starting of reaction
-rA = kC\0 (Q = CAo when 0=0)

dC
A ... cm3 wnnnio^ mol
or — = 17.4 —— x (0.0018)
dt mol ■ min cm3

Moles of acetic acid consumed per unit volume of reactor

~dCA ^ mol
= 5.6376 x KT5
dt cm' • mm

A c mol
Moles of acetic acid consumed = = 5.6376 x 10 — xV
dt cm • min

-dNA _ 1
= 5.6376 x 10-5 x 1.0165 x 106x 60 x ,
dt 103
-dNA
= 3.438 37 kmol/h (when 0 = 0 or at starting of reaction)
dt
Water formation rate = 3.438 37 kmol/h = 61.89 kg/h
Total flow rate of ternary azeotrope in starting of reaction

61.89 |
= = 214 kg/h
0.2892
It will contain 130.24 kg/h of butyl acetate, 22.4 kg/h of butanol and 61.89 kg/h of water
</»,, at starting or reaction = Zm, A,-

Table 10.2 Latent of Vaporization Data2

Process Engineering Channel

Component Latent heat of vaporization at 89.40C(A), kJ/kg

Butanol 625.39
Butyl acetate 330.2
Water 2284
@ProcessEng

(pv = 130.24 x 330.2 + 22.4 x 625.39 + 61.89 x 2284

<pv = 198 370.7 kJ/h = 55.103 kW
(p = (2.7285 x 1000 x 3.43837 + 0,,) x 1.05 = 218 139.9 kJ/h
= 60.5944 kW
As a heating medium saturated steam is used.
 668 Introduction to Process Engineering and Design

Let saturated steam pressure = 0.2 MPa a

Saturation temperature = 120.23oC
Latent heat of vaporization of steam, = 2201.6 kJ/kg

0 60 5944
Steam required ms = —= = 0.027 5228 kg/s = 99.08 kg/h
Xs 2201.6
Saturated steam side heat transfer coefficient h ', = 6000 W/(m2 • 0C) (assumed)
Inside heat transfer coefficient, /?,:
It is difficult to find the suitable correlation for the reacting mass side heat transfer
coefficient as the reaction is taking place, h, can be governed by boiling coefficient or by
convective film coefficient. If flat blade disc turbine agitator is used to improve the
reaction rate and to improve the convective film heat transfer coefficient, then
hi = hnB or hk whichever is less
where, hk = Convective film coefficient. W/(m2 • 0C)
Kb = Nucleate boiling coefficient, W/(m2 ■ 0C)
K
To calculate the convective film coefficient let the tip velocity of turbine agitator
V = 200 m/min = nDan
where, Da = Diameter of agitator
n = Rotational speed of agitator in revolutions per min
For flat blade disc turbine

^ellID = L042 = 0347m

3 3

n = —200— = 183 5 ^ 184

K x 0.347
For flat blade disc turbine, baffled vessel for Re > 400 (Ref. (5))

h D ( V1'14
0 67 033
= 0.74 Re n — (10.4)
^v,

nDlp
where. Re = —-— (10.5)

Table 10.3 Composition of Reaction Mass at the Starting of Reaction

Process Engineering Channel

Component Mass fractions at 0 = 0

Acetic acid 0.1405
Butanol 0.8595
Total 1.0000
@ProcessEng

Anix = 750 kg/m3

Viscosity of mixture

! _ w, ^ vv2 ^ 0.1405 | 0.8595

Amix Ai A2 Vaa As,,

As,, =
0-65 mPa ■ s at 90oC
 Process Design of Reactors

fiAA = 0.53 mPa ■ s at 90oC

/•'mix = 0-63 mPa ■ s

nD^ Pmjv (184/60) 0.3472 x 750

Reynolds number. Re = —f = 439 588
-3
/'mix 0.63x10

C„ /i C,) |T1jx /^mix

Pr = (10.6)
'kv|-ni• v

Table 10.4 Thermal Properties of Acetic Acid and Butanol

Component Cp, kJ/(kg • 0C) k, W/(m • 0C)

Acetic acid 2.1855 0.1557

Butanol 2.8763 0.164

Cpmix = ZCpi Wj = 2.1855 x 0.1405 + 2.8763 x 0.8595 = 2.78 kJ/(kg • 0C)

Thermal conductivity of liquid mixture can be calculated by Li method. (Equation
3.127 to 3.130 of Ref. 2)

^mix = 01" k-LX + 20,02 ^12 + 02' ^L2 (10.7)

In Eq. (10.7), 0, and 02 are parameters and do not represent heat loads.
ku =0.1557 W/(m ■ 0C) kL2 = 0.164 W/(m ■ 0C)
kl2 = 2(kll + ^r1 = 0.159 74 W/(m • 0C)
x
A-|V| 2V2
0i = and 02 = (10.8)
xl V] + X2 V2 x
\ + *2 ^2

0.1405
60 j
x, = mole fraction of acetic acid = = 0.1678
0.1405 0.8595 "l
+
60 J 74 J
x2 = 0.8322 = mole fraction of butanol

V, = molar volume of pure acetic acid = — = -^5- = 0.057 25 m3/kmol

p 1048
V2 = molar volume of pure butanol
Process Engineering Channel

= 0.086 m3/kmol
p 859.5
'.5

0.1678x0.057 25
0i = = 0.118 34
0.1678 x 0.057 25 + 0.8322 x 0.086
02 = 0.881 66
@ProcessEng

kmix = 0.118 342 x 0.1557 + 2 x 0.118 34 x 0.881 66 x 0.159 74

+ 0.881 662 x 0.164
0
= 0.163 W/(m C)

2.78 x 0.63 xl0-3xl03

Pr = = 10.744
0.163
 Introduction to Process Engineering and Design

/ N0. 14
h = 0.74 — Re061 Pr033 P
D,. PW

h: = 0.74 x x (439 588)0-67 x (10.744)a33 x 1

0.347
/i,. = 4594.25 W/(m2 • 0C)
Nucleate boiling coefficient for the boiling of azeotropic mixture can be determined by
Mostinski's equation.

\0.7 r \0.17 / \l.2 r 10

0.69 _p_
hnB = 0.104p" 1.8 + 4 —1 +iof— (6.56)
Pc Pc Pc

It is valid for single component boiling. But it can be used for close boiling range and
azeotropic mixture.
<p = 60.5944 x 103 W
For nucleate boiling ATm = 30.83oC (as decided earlier)
Heat transfer area provided with full height covered jakcket,
/lopr = TiDJi = kx 1.0547 x 1.042 = 3.4526 m2
(Assuming shell thickness, ts = 6.35 mm)
p = operating pressure bar = 0.9869 bar
pc = critical pressure, bar
Critical pressure of mixture pcm = I/>(7 y,- (Kay's rule)

Table 10.5 Critical Pressure of Azeotropic Mixture

Component of Mass Mole Molar Critical pressure,

Azeotropic mixture fraction fraction mass Pc, bar
Butyl acetate 0.6086 0.23 116 31.4
Butanol 0.1047 0.06 74 44.2
Water 0.2892 0.71 18 220.5

Total 1.0000 1.00

pcm = 0.23 x 31.4 + 0.06 x 44.2 + 0.71 x 220.5 = 166.43 bar

(pseudo-critical pressure)
Process Engineering Channel

f 60.5944 xlO3 Y'7 ...7 l9

hnB = 0.104 (166.43) ^ J (1.8/7, + 4/7,.12 + 10/7,l0)

where

Pr
r = —= = 5.9298 x 10"3
pc 166.43
@ProcessEng

hnB = 2524.95 W/(m2 • 0C)

Convective film coefficient, /?,• = 4594.25 W/(m2 - 0C) > hnB

Since nucleate boiling coefficient is less than the convective coefficient, it is taken for
heat transfer area calculations.
hj = 2524.95 W/(m2 • 0C)
 Process Design of Reactors

Jacket side or saturated steam side heat transfer coefficient, = 6000 W/(nr • 0C)
Thermal conductivity of reactor shell material (SS-304) = 16 W/(m • 0C)
Let thickness of reactor shell = 6.35 mm (Assumed but it should be decided based on
mechanical design)
Overall heat transfer coefficient:

1 1 1 £>„ IrKD^/D, ) £)„ ! D i

+ + + x—+ x (6.42)
Uo h0 hod 2kw Di ^ D, hid

^o_
D0 In
D
1 vA / Do 1 o 1
+ + X + X
u0 h,' 2kw Di hi Di /?,(/
Di = 1.042 m, D0 = Di + 2ts = 1.042 + 2 x 0.006 35 = 1.0547 m

1.0547
1.547 In
1 1 V 1.042 1.0547 1 1.0547 1
+ + X + X
U0 6000 2x16 1.042 2524.95 1.042 5000
U0 = 737.66 W/(m2 • 0C)
Heat duty, = 60.5944 x 103 W, = 30.23oC
Heat transfer area required

<p. 60.5944 x 10A ,

A = — = =2.7173 m2
U0 ATm 737.66 x 30.23
Outside heat transfer area provided with full height covered jacket
Aoav s 3.4526 m2
% Excess heat transfer area = 27.06%
Thus available heat transfer aera is sufficient.

10.4 CONTINUOUS FLOW REACTORS

All continuous flow reactors are steady state flow reactors. In a steady state flow
reactor, composition at any point is unchanged with time.
For continuous flow reactors, in-line mixers are used. In-line shear mixers
are developed for continuous degumming of edible oils. In-line static mixers are
Process Engineering Channel

effective in achieving desired mixing in continuous systems. In continuous

nitration, mixing of a reactant with mixed acid is very effective through a static
mixer. Similarly mixing of natural gas/naphtha vapour with steam prior to re-
forming can be carried out in an in-line static mixer. For removal of free fatty
acids from edible/non-edible oils with caustic soda solution, a static mixer is
used in a continuous plant. In Fig. 10.3, different designs, of static mixers are
@ProcessEng

shown.
Continuous flow reactors are used for achieving high throughputs. Also qual-
ity of product can be maintained at desired level once the operating conditions
are stabilised.
There are two ideal steady state flow reactors.
(a) Ideal plug flow reactor (b) Ideal mixed flow reactor
 Introduction to Process Engineering and Design

o o

Static Mixer-1

Static Mixer-2 (xv) Static Mixer-3

Fig. 10.3 Different Types of Static Mixers

10.4.1 Ideal Plug Flow Reactor1'2'3

It is also known as ideal tubular, unmixed flow, slug flow or piston flow reactor.
Ideal plug flow reactor has flat velocity profile. In this type of reactor, lateral or
radial mixing is permitted, but axial mixing is not permitted. Hence in ideal PFR,
the residence time in the reactor is same for all elements or particles of fluid.
Process Engineering Channel

Reactants

.Heat Transfer
Fluid Out
I Sieve Tray
Heat Transfer,
Fluid In
@ProcessEng

Products Reactants Products Fluid

(a) (b) (c)
Shell and Tube Heat exchanger Single Coiled Tubular Sieve Tray Type Reactor
Type Reactor Reactor
Fig. 10.4 Plug Flow Reactors
 Process Design of Reactors

Ideal PFR is defined by two criteria.

(a) Over any cross section of ideal PFR, the mass flow rate, velocity and the
fluid properties like pressure, temperature and composition are uniform
and the same do not change with time.
(b) There is negligible diffusion relative to bulk flow or no element of fluid
overtaking or mixing with any other element ahead or behind.
In ideal PFR, composition at any point is not changing with time but it changes
with length or axial distance in reactor.
Industrial plug flow reactors can be fixed bed catalytic reactor, packed tower
type reactor, tubular reactor with very high length to diameter ratio and zigzag
path, shell and lube heat exchanger, double pipe heat exchanger, sieve tray tower,
etc. Working volume of ideal PFR can be determined by using following equation.

xA
y r dXA
-^=\— (10-9)
o ~'A
where, V = Working volume of ideal PFR, m
Fa0 = Molar flow rate of limiting reactant A at inlet, kmol/s
XA = Fractional conversion of liming reactant required

dCA
-rA = —-— = Rate of chemical reaction in kmol/(nr • s)
df
Residence time required in ideal PFR for the desired extent of given reaction
can be determined by following equation.

Xa
y y dXA
0
=cM-jh=ir=c*° S ^7- (iai0)
'Ao 'o o A
6 = Residence time required, s
V0 = Volumetric flow rate of reacting fluid at inlet, m3/s

10.4.1.1 Advantages and Disadvantages of Plug Flow

Reactors over Mixed Flow Reactors

(a) Advantages:
Process Engineering Channel

(i) For any positive order reaction, plug flow reactor require minimum volume
among all types of continuous flow reactors. Volume required by ideal PFR
is very much less than the same by ideal mixed flow reactor, particularly for
a higher order reaction with higher desired conversion.
(ii) Plug flow reactor does not use moving mechanical parts and hence it is
suitable for high pressure reaction system, corrosive reaction system and
@ProcessEng

for the reaction system which involves the use of a toxic gas.
(b) Disadvantages:
(i) Cost per unit volume of plug flow reactors is higher than the same of mixed
flow reactor.
(ii) It requires high investment cost for lower conversion and lower order
reaction.
 Introduction to Process Engineering and Design

10.4.1.2 Few Industrial Examples of Plug Flow Reactors

(i) Conversion of ethylene to low density polythylene (LDPE)

(ii) Hydrolysis of ethylene oxide to ethylene glycol.
(hi) Fixed bed catalytic reaction.
Some examples are as follows:
(a) Conversion of NH3 from the mixture of N2 and H2
(b) Melhanol synthesis reaction
(c) Steam reforming reaction.
(d) Conversion of synthesis gas (H2 + CO) to methanol
(e) Air oxidation of methanol to formaldehyde
(iv) Olefin production by steam cracking, e.g. ethylene
(v) Conversion of ammonium carbamate to urea in an autoclave.

10.4.2 Ideal Mixed Flow Reactor

It is also known as the back mix reactor (BMR), ideal continuous stirred tank
reactor or as constant flow stirred tank reactor. In ideal mixed flow reactor (MFR),
composition within the reactor is uniform throughout and does not change with
time. Hence, in ideal MFR (or in ideal BMR or CSTR) exit stream from the
reactor has the same composition as the fluid within the reactor.
Among all types of continuous flow reactors, ideal mixed flow reactor requires
maximum volume for the given positive order reaction. So, volume required by
ideal mixed flow reactor (Vm) is greater than volume required by ideal plug flow
reactor (Vp. Ratio yjVp increases with increase in order of reaction and also
with increase in required conversion.
In an ideal CSTR, once the reactants enter into the reaction mass, they
immediately (practically within no time) achieve final required composition. This
is not due to very fast reaction but this is merely due to the dilution of reactants
by the products. Actually, the rate of reaction is minimum in ideal CSTR, compared
to all types of continuous flow reactors, as it provides minimum concentration of
reactants during reaction.
In an ideal CSTR, not only composition but temperature is also uniform through-
out. Temperature of product stream is same as that within the reactor.
Industrial mixed flow reactors can be:
Process Engineering Channel

(a) Agitated vessel type reactor

(b) Sparged vessel (including gas induced agitator type) or bubble column type
reactor
(c) Loop reactor (with recirculation, recirculating pump and external heat
exchanger)
(d) Jet reactor with recirculation through an ejector
@ProcessEng

Volume required by ideal mixed flow reactor is determined by following the

equation.

—- — (10.11)
Fao -rA
Residence time required in ideal mixed flow reactor for the desired extent of
given reaction is determined by the following equation.
 Process Design of Reactors

V V Xa
0=CAo-^ = ^ = CAo^ (10.12)
F
Ao K -rA
where, 0 = Residence time required, s
CAo = Initial concentration of limiting reactant A, kmol/m3
V= Working volume of reactor, m3
V0 = Volumetric flow rate of reacting fluid at inlet, m3/s
XA = Fractional conversion of limiting reactant A

10.4.2.1 Advantages of Ideal Mixed Flow Reactor

(i) Temperature is easier to control. Good mixing and lower rate of reaction
(lower rate of heat generation in case of exothermic reaction) makes the
temperature control easier. In the entrance portion of plug flow reactor and
in starting period of batch reaction, rate of reaction is very high and hence
temperature control is difficult. Agitated vessel type ideal mixed flow reac-
tor also provides higher heat transfer coefficient compared to packed tower
type or sieve tray type plug flow reactor which are normally operated in
adiabatic manner.
(ii) Ideal mixed flow reactor may require less fixed cost compared to ideal plug
flow reactor for lower order reaction with lower equilibrium conversion
because cost per unit volume of mixed flow reactor is less than the same of
plug flow reactor.
(iii) Polymerization reactions can be nicely controlled in ideal CSTR compared
to the same in ideal PFR. (e.g. desired molar mass of polymer can be easily
achieved.)
(iv) Fine catalyst particles can be effectively suspended throughout the liquid
reaction system with agitated vessel type mixed flow reactor.
(v) For highly viscous fluid or slurry solution, agitated vessel type mixed flow
reactor provides higher heat transfer coefficient and mass transfer coeffi-
cient, compared to plug flow reactor.

/ 0.4.2.2 Disadvantages of Ideal Mixed Flow Reactor

(i) Ideal mixed flow reactor provides the minimum rate of reaction among all
types of continuous flow reactors. Hence, it requires maximum volume
among all types of continuous reactors for any given positive order reaction
and required conversion.
Process Engineering Channel

(ii) Change over to other product is difficult compared to stirred tank batch
reactor.

10.4.2.3 Industrial Examples of Mixed Flow Reactors

(i) Carbonylation of methanol gives acetic acid in presence of liquid phase
catalyst
(ii) Oxidation of acetaldehyde to acetic acid in presence of fine KMn04 (potas-
@ProcessEng

sium permanganate) particles as catalyst

(iii) Syrene to polystyrene by solution polymerization.
(iv) Slurry polymerization of propylene to polypropylene
(v) Chlorination of benzene to chlorobenzene by continuous process
(vi) Oxidation of toluene to benzoic acid.
(vii) Vinyl chloride to polyvinyl chloride by emulsion and suspension polymeri-
zation
 Introduction to Process Engineering and Design

Example 10.2
A homogeneous liquid phase reaction
A —>/?,
takes place with 50% conversion in a mixed flow reactor. Its rate equation is

dCA ,
-rA=^- = kC2A
A A
dt
(a) What will be the conversion if this reactor is replaced by the one, 6 times larger
reactor and all else remaining unchanged ?
(b) What will be the conversion if the original reactor is replaced by a plug flow reactor
of equal size and all else remaining unchanged ?
Solution:
Performance equation of ideal mixed flow reactor is

(10.11)
f
ao -rA

P ^a ^A 0.5
F
ao kCl kCla-XAf kCAo (1-0.5)2 kCl
(a) For V = 6F (where V = volume of larger reactor)

X x
V A a
(i)
f
ao -rA kCl i<c2Ao {\-xAy

V ^ V —
Also 6
— = 6-^— 6x
= 6x—(2)
Fao Fao kC2Ao

x
a 12
From Eq. (1) and (2), —-
kC^o (1- X A ) kCl
12(1 -X^2 = Xa
12 (I - 2 XA + XA) = XA
12 - 24 + 12 XA -XA = 0
12X2 _ 25 XA + 12 = 0
X^2 - 2.083 33 X^ + 1 = 0
Process Engineering Channel

XA= 1.333 or X^ = 0.75

XA can not be greater than 1; hence X^ = 0.75
Hence, six times larger ideal mixed flow reactor will give 75% conversion.
(b) Knixed flow = ^plug flow = ^
Performance equation of ideal plug flow reactor

XA X
@ProcessEng

v r dXA r dXA
=
f
= j ^- j T (10-9)
ao o 'a o kCAo (1 - XAp )-
where, XAp = Fractional conversion of reactant A in ideal plug flow reactor

dp
Let P = I - xap ' hence = -1
dX Ap
 Process Design of Reactors

-2+1 \-p_
V_ 1 f dp p
x
F'ao ~ kCl 1 P2 kC Ao -2 + 1 kCAo p

V i x AP

FAo kcl t-xAP

V
For ideal mixed flow reactor
F.Ao kC2
KL -Ao

2F.Ao
V= 'mixed plug

2 FAo ^ 1 X AP

kCAo FAo kcl i-xAP

2 - 2Xap = XAp
XAP = 2/3 = 0.6667
Hence, if the original ideal mixed flow reactor (giving 50% conversion) is replaced by
an ideal plug flow reactor of equal size, then conversion will be 66.67%.

Example 10.3
The following data have been obtained on the decomposition of gaseous reactant A in a
constant volume batch reactor at 100oC.

Table 10.6 Time vs Pressure Data of Decomposition of A

0, s pA, atm 0, s pA, atm

0 1 140 0.25
20 0.8 200 0.14
40 0.68 260 0.08
60 0.56 330 0.04
80 0.45 420 0.02
100 0.37
Process Engineering Channel

The stoichiometry of the reaction h2A = R + S.

(a) What size of plug flow reactor (in liters) operating at 100oC and 1 atm can treat 100
moles of A/h in a feed consisting of 20% inerts to obtain 95% conversion of A?
(b) What conversion of A can be expected in mixed flow reactor of volume V = 208 L,
for the same identical feed and identical operating conditions?
Solution:
First rate equation, based on constant volume batch reactor data, must be determined.
@ProcessEng

From the data, at 0 = 420 s, pA is 0.02 atm means it is reduced to a value very close to
zero. Hence, given reaction is irreversible reaction,
Assuming first order irreversible reaction.

-dC*
-'a = = kCA
dd
 Introduction to Process Engineering and Design

PA = CART

1 dpA pA
=k
RT dO RT

dpA
= kpA
dd

Pa 0
r dpA
J = kjde
Pao Pa

/ \
Pa
-In = ke
Pao
From the given data, following table can be prepared.

Table 10.7 Tabulation of Calculations of Integral

0, s pA, atm -In

[Pao

0 1.00 0.0000
20 0.80 0.2230
40 0.68 0.3856
60 0.56 0.5800
80 0.45 0.7980
100 0.37 0.9940
140 0.25 1.3860
200 0.14 1.9660
260 0.08 2.5260
330 0.04 3.2200
420 0.02 3.9100

Pa
The graph of -In vs 6 (Fig. 10.5) is a straight line passing through origin.
Process Engineering Channel

Pao
Hence, given reaction is irreversible reaction and is of 1st order.
k = 0.009 76 s-'
-rA = 0.009 76 CA mol/(L • s) = 35.136 CA mol/(L • h)
(a) Performance equation of ideal plug flow reactor,
x,
3 dX ,
@ProcessEng

o -rA
Reaction 2A ^ R + S, with 20% inert

^=1 ~^=o
£a =
^=o
£a = 0, as total number of moles of reaction system are not changing
 Process Design of Reactors 679

Av
^ 2.0
S

Av

1.0

At 0 70413
slopes- — •
At 72 144
» 0 009 76
40 "80 120 160 200 240 280 320 360 400 440
Process Engineering Channel

9, seconds
Fig. 10.5 Determination of Order of Reaction

x.
dX. dX,
s=cAo 1
u kCAo (I-XA) k o (1-X^)
-\n(l-XA)=k0
@ProcessEng

1
0 = --ln(l-XA) = ' In (1 -0.95) = 307 s
A
k 0.009 76

9=^.-^ = 307 8
F
Ao
 Introduction to Process Engineering and Design

F F
AO ^ AO
Working volume of reactor, V = 6—— = 307
CAo

Pao
CAo = , pAo =p,y. 0.8 = 0.8 atm (20% inerts)
R1

CAn = — = 0.026 16 mol/L

(273+100) x 0.082
FAo = 100 mol/h

307 xl 00 x (1/3600)
V= = 326 L
0.02616

(b) For ideal mixed flow reactor,

V XA XA
F r
AO A ^CA„ (1 XA)

XA kCAoV 0.009 76 x 0.02616 x 208

1-^ FAO 1
100 x
3600

——= 1.912
• " xA
XA = 0.65
65.65% conversion of reactant A can be expected in ideal mixed flow reactor.

Example 10.4
It has been reported that the reaction
CH2OH + NaHCO, -> CH2OH + NaCl + C02

CH2C1 ch2oh
A B
Process Engineering Channel

Ethylene Sodium Ethylene Salt Carbon

Chlorohydrin Bicarbonate Glycol Dioxide
is elementary with rate constant k = 5.2 L/(mol • h) at 820C. On the basis of this informa-
tion it is intended to construct a pilot plant to determine the economical feasibility of
producing ethylene glycol from two available feeds, a 15 mass % aqueous solution of
sodium bicarbonate and a 30 mass % aqueous solution of ethylene chlorohydrin.
(a) What volume of tubular (plug flow) reactor will produce 20 kg/h ethylene glycol at
@ProcessEng

95% conversion of an equimolar feed produced by initimately mixing appropriate

quantities of the two feed streams?
(b) What size of mixed reactor is needed for the same feed, conversion and production
rate as in Part (a)?
Assume all operations at 820C at which specific gravity of the mixed reacting fluid is
1.02.
 Process Design of Reactors 681

Solution:
(a) Performance equation of ideal tubular reactor

\/ ^ dXA
7^=1— (10.9)
A
Fao "
Here given reaction is elementary reaction. Hence rate equation is corresponding to
stoichiometric equation.
-rA = kCA CB
for equimolar feed, CAo = CBo and CA = CB

-r-A = kC2A

V
p ^ ^ dXA
f
ao o kC2A 0 kCAo (1 — XA)

VP rlX
aA x.,
2 [ A 1
F
Ao O il-XA)2 l-X, \-XA l-Xf
0

VP 0.95
5.2 XC:
Fa0 1-0.95
For equimolar feed and based on stoichiometric equation,
FAo x 0.95 = Moles of ethylene glycol produced (for 95% conversion)

20 kg/h
F
Ao =
0.95 x Molar mass of ethylene glycol

20
FAn = — = 0.3396 kmol/h
^ 0.95 x 62
Total Mass of Feed:
mF = Mass flow rate of ethylene chlorohydrin solution + mass flow rate
of sodium bicarbonate solution.
mF = (0.3396 x MEC + mass of associated water) + (0.3396 x MSB +
mass of associated water)
Process Engineering Channel

where MEC = Molar mass of ethylene chlorohydrin = 80.5 kg/kmol

Msb = Molar mass of sodium bicarbonate = 84 kg/kmol

0.3396x80.5
mF = 0.3396 x 80.5 + x 0.7
0.3

f (0.3396x84) )
+ 0.3396 x 84 + x 0.85
I 0.15 )
@ProcessEng

= (27.3378 + 63.7882) + (28.5264 + 161.6496)

= 281.302 kg/h
Density of reacting fluid = 1020 kg/m3

= 281.302 = 0 2758 m3/h

1020
 682 Introduction to Process Engineering and Design

^Ao 0.3396 i TO i -j i / 3
C4„ = = = 1.2313 kg/m
0.2758
k = 5.2 L/(mol ■ h) = 5.2 m3/(kmol - h)

5.2 X x-^ = -0^_

^ FAO 1-0.95

(1.2313)2 nos
5.2 x — xV =- u•y:,
p
0.3396 1-0.95
Vp = 0.818 45 i3 ='
= 818.45 L
(b) For ideal mixed flow reactor

FAo -rA kC2Ao{\-XA)

Fao XA
F =
m
~ kC2Ao i\-XA)2

v 0.3396 0.95
2
~ 5.2x(1.2313) (1-0.95)2

Vm = 16.369 m3 = 16 369 L

10.5 DEGREE OF COMPLETION OF REACTION

Chemical engineers are familiar with degree of conversion of a reaction which is

well defined as the ratio of moles of limiting reactant consumed to that in the
feed. However, it is not possible to define the degree of conversion of reaction(s)
in all cases. Chief reason for not able to define the conversion clearly is compo-
sition of feed in which more than one reactant react simultaneously (i.e. parallel
reactions) and degree of completion of each reaction is unknown. Under these
circumstances, degree of completion of reaction is defined in several ways.
Consider a classical reforming reaction of hydrocarbons with steam. There
are a number of hydrocarbons present in the feed. They react simultaneously
Process Engineering Channel

with steam and produce carbon monoxide, carbon dioxide and hydrogen.
CgH^ + 6 H20 ^ 6 CO + 13 H2
C5H12 + 5 H20 ^ 5 CO + 11 H2

C2H6 + 2 H20 ^ 2 CO + 5 H2
@ProcessEng

CH4 + H20 ^ CO + 3 H2
CO +H2O ^CO2 +H2
Study of equilibrium conversions of competing reactions reveal that while
most hydrocarbons reform to hydrogen, methane is not always fully reformed.
Thus, degree of completion of the reforming reaction is judged by methane slip
(i.e. mole % methane in outgoing gas mixture).
 Process Design of Reactors

Edible oils are hydrogenated to produce hydrogenated fat. Basically edible oil
is a mixture of (mostly) triglycerides of fatty acids. Each edible oil has different
composition of variety of fatty acids. It is not possible to know the exact compo-
sition in terms of fatty acids for each batch of oil. These fatty acids may be satu-
rated or unsaturated. The degree of unsaturation is measured by titration with
potassium iodide and is known as iodine number. Higher the iodine number,
higher is the unsatu-ration. When hydrogenated, double and triple bonds open up
and saturation takes place. For this hydrogenation reaction, degree of completion
is measured by reduction in the iodine value of the oil.
Alkyd resins are produced by reacting an organic acid such as phthalic anhy-
dride, benzoic acid, etc. with glycerine or other polyols. During the course of
esterification reaction, acid is consumed. Degree of completion of this process is
measured by the final acid value of the product.
In demineralization of water, cations are removed in the cation exchanger while
anions are removed in the anion exchanger. While bi- and tri-valents are removed
on a priority, monovalent ions are not easily removed. Hence, degree of demineral-
ization (i.e. degree of completion of each ion exchanger) is measured by sodium
and chloride slips, respectively.
Several other examples can be cited for the degree of completion.
It can, therefore, be visualized that the degree of completion of reaction is
defined in terms of a measurable parameter.
These reactors are designed for desired completion of reaction. For such
reactions, rate of reaction need not be defined as for pure chemical reaction (see
Example 10.5). It is normally expressed in terms of measurable index with respect
to other parameters.
Rate of reaction of manufacture of alkyd resin can be expressed in terms of
disappearance of acid value. Typical kinetic expression could be
AV = Xe+Y
where, AE = Acid value after time 0
6 = Time
X and Y are constants. These could be determined by laboratory and pilot plant
studies.
In case of hydrocarbon reforming, methane slip is dependent of pressure and
temperature. It can be defined in an impirical form in terms of pressure and tem-
Process Engineering Channel

perature.
Cc^Xp'f+Y
where, CCH4 = Concentration of methane (mole %) at exit
p = Operating pressure
T = Operating absolute temperature
X, a, b and Y are constants.
Alternately, degree of approach is used to define completion of reforming
@ProcessEng

reaction. Based on actual methane slip and pressure, equilibrium temperature is

found from the standard chart. Difference between actual operating temperature
and equilibrium temperature (read from the graph) is defined as the approach.
While designing a chemical reaction system, degree of conversion is used for
well defined reaction, if known. For all other systems, desired degree of completion
is defined and the system is designed accordingly. In case of ammonia manufacture,
conversion per pass is commonly expressed as the reaction is well defined.
 Introduction to Process Engineering and Design

10.6 MIXING FOR THE DIFFERENT TYPE OF REACTION

SYSTEMS6

For the better mixing or better mass transfer rate, an agitator, a circulating pump,
etc. are used as mixing tools. Some new techniques are also available for the
same. Selection of agitator for the given reaction system depends on the viscosity
of reaction mixture, homogeneity of the reaction system, desired duty, etc.
Following are the guidelines for the selection of agitator (or other technique)
for the different type of reaction systems.
(i) Homogeneous Liquid Phase Reaction System:
If the viscosity of homogeneous liquid phase system is less than 500 mPa •
s then flat blade turbine stirrer (with four or six flat blades on disc as shown
in Fig. 10.2(v)) or Pfaudler impeller (as shown in Fig. 10.2(ix)) can be
selected. They are used with side baffles. These agitators create the cur-
rents mainly in radial and tangential directions. Use of side baffles are re-
quired to avoid the vortex formation.
If the viscosity is in the range of 500 to 5000 mPa • s, cross beam, grid
and blade stirrers (Ref. Fig. 10.2(xiv), (xvii) and (xviii)) are suitable for
homogeneous liquid. For the lower viscosity (nearer to 500 mPa • s), side
baffles are used with these types of agitators. For the higher viscosity (nearer
to 5000 mPa • s), side baffles are not required.
For highly viscous liquid (viscosity, /u > 5000 mPa ■ s), anchor stirrer
(Ref. Fig. 10.2(xi)) is selected. Normally the diameter of anchor agitator is
90% or more of the inside diameter of tank. It rotates with keeping a close
clearance with inside surface of shell. It removes the sticky material from
the heat transfer surface and thereby improves heat transfer coefficient. But
this agitator provides poor mixing. Anchor agitator can be used in
conjunction with a higher speed paddle or other agitator to improve the
mixing. Other agitator is usually turning in the opposite direction. Miscible
liquids are often simply mixed in pipelines by using a static mixer. The
deflection elements in static mixer divide the stream into two streams and
turn each through 180°, so after passing through N elements the stream has
been blended 2N times.
(ii) Gas-Liquid Reaction:
Process Engineering Channel

(a) Gas itself creates the axial currents. Hence for the gas-liquid reaction
system suitable agitator is that which creates the current in tangential
and radial directions. Hence, coventional flat blade turbine agitator (as
shown in Fig. 10.2(ii) and 10.2(v)) is used for such applications in
which separate sparger is provided.
(b) Gas induction type hollow agitator is new innovation for this application.
@ProcessEng

Special type of impeller (as shown in Fig. 10.12) is attached with hollow
shaft. In the upper part of the hollow shaft, windows are provided for
gas suction. Gas enters from these windows and discharges through
the lowest part of the impeller. The agitator operates on the principle of
water jet ejector. The suction so generated blows the stirrer edges during
the rotation and hence gas enters through windows and discharges from
 Process Design of Reactors

the bottom of impeller to liquid pool. A specially designed impeller

vigorously disperses the gas bubbles and creates a mixture akin to a
boiling liquid. Gas bubbles react with liquid as they rise. Unreacted
gas is reinduced into the liquid through windows. Recirculation of gas
is important because bubbling of gas only once through the liquid does
not use it up completely. It offers the following advantages.
(i) It provides vigorous gas liquid mixing.
(ii) It substantially increases gas-liquid interfacial area of contact and
enhances gas-liquid mass transfer rate.
(iii) It reduces reaction time considerably for the gas-liquid reaction in
which overall reaction rate is governed by rate of mass transfer.
(iv) It provides very high vessel side (i.e. inside) coefficient which ap-
proaches a boiling coefficient.
(v) It is also the best choice for the gas-liquid reaction with suspended
solid catalyst. Example: hydrogenation in presence of suspended
Reiny Ni catalyst.
It is used for hydrogenation, alkylation, ozonization, oxidation, amination,
etc. reactions.
(c) Jet reactor is a new design of reactor which can be used to achieve the
excellent gas-liquid mixing. As shown in Fig. 10.1 (i). Jet reactor con-
sists of a reaction autoclave, a circulation pump, an external heat
exchanger and a venturi type ejector. Jet reactors are available in the
capacities from 0.02 m3 to 100 m3, operating pressure up to 200 bar,
operating temperature up to 350oC and in variety of materials of con-
structions like stainless steel, Hastelloy, Monel, etc. This reactor can
be used for the viscosity of reaction mixture up to 500 mPa • s and for
gas-liquid reaction with suspended solid particles (solid catalyst load
should be less than 10% by mass).
Following are the advantages of jet reactor over agitated vessel type
reactor.
(i) Length to diameter ratio of jet reactor is higher than the same of
agitated vessel. Hence, jet reactor requires less cost particularly
Process Engineering Channel

for high pressure reactions.

(ii) The external heat exchanger (instead of internal coil or jacket) can
be built as large as needed and is not limited by the reactor geometry.
Sufficient heat transfer area could be made available for accurate
temperature control even if the reactor is operated with reduced
working volumes.
@ProcessEng

(iii) The maximum power input per unit volume is often a limiting factor,
especially for large reactors with an agitator. Since there is no
agitator in the jet reactor, this limitation does not exist.
The circulation pump can provide very high power per m3 of
working volume if it is required to achieve the desired mass trans-
fer rate.
 Introduction to Process Engineering and Design

(iv) The down flow jet ejector forms fine gas bubbles in the liquid and
creates high mass transfer rates.
Jet reactor is used for hydrogenation, alkylation, carbonylation
oxidation, halogenation, amination, phosgenation, etc. reactions.
Jet reactor is a type of loop reactor.
(d) Another loop reactor is a monolith catalytic reactor [Fig. 10.1 (j)].
Monolithic structure of the base carrier is impregnated with a nobel
metal (such as platinum, palladium, etc.). Liquid is circulated through
a pump and passed through the catalyst with induced gas. Originally
developed for emission control from auto vehicles (for catalytic
oxidation of carbon monoxide), monolithic structure is found equally
effective for chemical reactors. Monolithic structure provides large
surface area and hence low concentration of catalyst (0.5 to 1%) on the
structure is sufficient for accelerating the reaction. The design is claimed
to be highly effective in hydrogenating a nitro compound to an amine.
(e) Recent innovation for gas-liquid reaction is to convert the heterogene-
ous gas-liquid reaction into single homogeneous phase; supercritical
phase by changing the operating conditions. Foreign substance (such
as carbon dioxide, propane, etc.) is added to the reaction system to get
the homogeneous supercritical phase.
Examples:
(A) Hydrogenation of oleochemicals at supercritical single phase conditions:
In this case, propane is added to reaction system. Supercritical propane
dissolves both hydrogen and oil and creates the single homogeneous
supercritical phase. This supercritical phase is contacted with catalyst
and it gives very high overall rate of reaction and higher selectivity. To
create the necessary single phase (supercritical phase) conditions,
operating pressure is kept near 150 bar, temperature of 280oC and
propane is added to the extent of 5 to 6 times product mass.
Hydrogenated product will have less of rram-isomer and less free fatty
acids.
(B) Oxidation of waste water at supercritical phase conditions7:
It is carried out at 3740C and 22.1 MPa a pressure. It is carried out
Process Engineering Channel

between supercritical wastewater and oxygen. Enhanced solubility of

oxygen in supercritical water eliminates mass transfer resistance and
provides very high mass transfer rate. Residence time required in reac-
tor is only 60 seconds for 99.98% COD reduction.
(hi) For gas-liquid reaction with suspended solid particles: Simple loop reactor
or jet reactor are also valid for gas-liquid reaction with suspended solid
@ProcessEng

particles, except with static mixer. Oxidation of acetaldehyde to acetic acid

in presence of potassium permanganate can be classified in this category,
(iv) For liquid - liquid reaction: Such type of reaction mixture is a mixture of
two immiscible liquids; e.g. nitration of benzene using mixed acid, reaction
of phenol with an alkali, etc.
 Process Design of Reactors

For the better mixing of two immiscible liquids, axial currents are more
important. If the viscosity of liquid-liquid mixture is less than 500 mPa ■ s,
then pitched blade turbine or propeller are more effective. For smaller ves-
sel propeller (Fig. 10.2(i)) and for larger vessel pitched blade turbine
(Fig. 10.2(iv)) is suitable. For higher viscosity (ju > 400 mPa • s), agitator
which contains cross beam with inclined blades (Fig. 10.2(xiv)), can be
selected for liquid-liquid reaction system.
For nitration reaction, a loop reactor with a static mixer can be used.
Mixed acid can be fed into the static mixer (at a controlled rate.) Heat ex-
changer, located on downstream of the static mixer, can remove exothermic
heat of reaction effectively. It is claimed that in such a system chances of
side reaction (such as dinitro formation) are minimal.
(v) For liquid-solid reaction:
In this case entire surface of solid particles must be accessible to the liquid.
Hence, all solid particles must be suspended in the liquid. For the suspen-
sion of solids, axial currents are important. Hence, for the lower viscosity
of slurry, 45° pitched blade turbine or propeller can be selected. For more
viscous slurry (500 mPa • s < ^ < 5000 mPa • s) cross beam with inclined
blades and for highly viscous slurry, helical ribbon (Fig. 10.2(xvi)) can be
selected. If solids are sticky and heat transfer by jacket is important, then
anchor agitator in conjunction with off-center propeller or pitched blade
turbine is preferred.

Example 10.5
Hydrogenation of edible oil is carried out to produce 'Vanaspati' (hydrogenated fat) in
presence of nickel catalyst in a batch reactor. In the standard age old process, edible oil
is hydrogenated at about 2 bar g and 160-175 0C in 8 to 10 hours (excluding heating/
cooling). During this period, iodine value of the mass is reduced from 128 to 68. Final
mass has a melting (slip) point of 390C. The batch reactor [Fig. 10.1(a)] has a jacket for
heating the initial charge with circulating hot oil. Cooling requirements are met by pass-
ing cooling water in internal coils.
In a newly developed Jet Reactor [Fig. 10. l(i)], it is planned to complete the reaction
in 5 hours by improving mass transfer in the reactor and cooling the mass in external
heat exchanger, thereby maintaining near isothermal conditions. Figure 10.6 shows the
Process Engineering Channel

suggested scheme.
Soybean oil, having iodine value (IV) of 128 is to be hydrogenated in the jet reactor at
5 bar g and 1650C. Initially the charge is heated from 30oC to 140oC with the circulating
hot oil in external heat exchanger. Hydrogen is introduced in hot soybean oil and pres-
sure is maintained in the reactor at 5 bar g. Reaction is exothermic and the temperature
of mass increases. Cold oil flow in the external heat exchanger controls the temperature
@ProcessEng

at 1650C as per the requirement, IV reduction is desired up to 68 when the reaction is

considered over. Thereafter hydrogenated mass is cooled to 60oC in about 1.5 h before it
is discharged to filter. 150 kg spent nickel catalyst is charged with soybean oil while
fresh 5 to 10 kg nickel catalyst is charged at intervals in the reactor under pressure. A
bleed is maintained from the system to purge out water vapour and non-condensables.
Design the jet reactor for the following duty.
 Introduction to Process Engineering and Design

*- M
3 '>
-3

c
^
o a> _
r* on v
2
^ 8 ^
CQ Di c/D

n
-iJ
X

-Q
o UJ

/ c
.0
0
c
I) 0)
1
O I
I-HH
c

o 0
^op :S
uo
t-J -^h—

o
CK
pinbiq

■^h— »o
d

oi
Process Engineering Channel

I a V)
cj wa>
U>

H
o v> H

T3 ^H-
@ProcessEng
 Process Design of Reactors 689 [

(i) Charge = 101 soybean oil with 128 IV

(ii) Average molar mass of soybean oil = 278.0
(iii) Average chain length of fatty acids = 17.78
(iv) Product specifications: 68 IV, 390C melting point (max.)
Assume linear drop of IV in 5 hours.
(v) Average exothermic heat of reaction = 7.1 kJ/(kg IV reduction)
(vi) Hydrogen feed rate = 110 to 125 NnvVh
Bleed rate = 1 to 2 NnrVh
(vii) Thermic fluid or oil is used as both, heating medium in starting of reaction and
cooling medium in running of reaction.
(viii) Cooling water is available at 2 bar g and 320C. A rise of 50C is permitted. Cooling
water is used for cooling the oil from 80oC to 70oC in oil cooler (HE-2) of oil cycle.
(ix) Assume following properties of fluids for the design.

Table 10.8 Average Properties of Edible Oil and Circulating Oil

Properties Soybean oil or Hardened fat Circulating oil (thermic fluid)

Density, kg/L 0.825 0.71

Specific heat, kJ/(kg • 0C) 2.56 2.95
Viscosity, mPa • s 2.0 0.5
Thermal conductivity, W/(m • 0C) 0.16 0.1

Solution:
10000
Volume of liquid inside the jet reactor, V, = = 12 121.2 Ls 12.12 m3
0.825
TT j
V,L = —
^ D~I h,L + inside volume of bottom head

where, Di = Inside diameter of jet reactor, m

hL = Height of liquid inside the shell of jet reactor, m
Let hL = 1.5 Dj
Type of bottom head = Torispherical

Inside volume of torispherical head = 0.084 672 D] + Dj SF

Process Engineering Channel

Let 5f= 1.5 in = 0.0381 m

12.12 = - Dj (1.5 Z>) + 0.084 672 Dj + — x 0.0381 Dj

4 ' ' 4
12.12 = 1.26 28 Dj + 0.029 92 Dj
D, =2.115 m
hL = 1.5 x2.115 = 3.1725 m
Let total height of shell of reactor, // = 2 x 2.115 = 4.23 m
@ProcessEng

Design of external heat exchanger:

Type of heat exchanger: BEM type shell and tube heat exchanger
Heat duty of HE-1 for cooling period:

kg of reaction mass
0C = Average heat of reaction x IV reduction x
Reaction time
 690 Introduction to Process Engineering and Design

10 000
= 7.1 x (128 - 68) x —-— = 852 000 kJ/h = 236.67 kW

Let circulation rate of soybean oil = 71 m3/h = 58 575 kg/h

m = 58 575/3600 = 16.27 kg/s, CL = 2.56 kJ/(kg • 0C)
AT = 5.6820C
Hence, in heat exchanger, temperature of circulating stream of reacting mass is to be
reduced from 1650C to 159.3180C. It is cooled by thermic fluid entering at 70oC and
leaving at 80oC.
Mass flow rate of cooling oil m0:

236 67
m0 = - = 8.023 kg/s = 28 883 kg/h
2.95 (80-70)
Mean temperature difference:
A'4 = LMTD
.MTD x jF,

(165-80)-(159.318-70)
LMTD =
In [(165-80)/(159.318-70)J
LMTD = 87.1410C
For 1 -1 heat exchanger, T, = 1.
Hence, A4 = 87.1410C
Allocating reacting oil stream on tube side and thermic fluid (cooling medium) on
shell side.
Calculations of /?,: Let tube OD, d0 = 25.4 mm
For 16 BWG tube, tube ID. d, = 22.098 mm
(Table 11-2, ofRef. 2)
Let tube side velocity, u, = 1.5 m/s
M,
M

C, = u,p =
_ m
G,
a,

m 58575/3600
a.1 — — = 0.013 148 m2
G, 1237.5
Process Engineering Channel

N,
a.t N
N
,>
where, Nt = Total number of tubes, Np = number of tube side passes = 1

0.013148
N, = = 34
2
- x (0.022 098)
4
@ProcessEng

d.G. 0.022 098x1237.5

Rc, = -L-L = = 13 673.14
F 2x10

CpF 2.56x2x 10"3 xlO3

J
Pr = - — = = 32
k 0.16
 Process Design of Reactors 691

Dittus-Boelter's equation
/ \0.14
08 033 P
= 0.023 Re Pr (6.19)
</ P
\ r-w
0.16
h, = 0.023 x x (13 673.14)0-8 x (32)\0.33
0.022 098
^ = 1063.87 W/(m2 • 0C)
Calculations of hn:
For 25.4 mm (1 in) OD and 31.75 (1.25 in.) triangular pitch, from Table 6.1 (f), for
N, = 24, BEM type 1.1 heat exchanger.
Shell ID, Ds = 203 mm
Let baffle spacing, Bs = 150 mm
Type of baffle = 25 % cut segmental
Shell side flow area

Pi -dp
4= x Ds x Bs (6.29)
p,
31.75-25.4 , 0
Ar = x 0.254 x 0.15 = 7.62 x lO"3 m2
31.75
m.
Shell side mass velocity, Gs = (6.30)

8 023
G = " = 1052.89 kg(m2-s)
7.62 xlO"5

1052.89
u
s= = 1.483 m/s
Po 710
Shell side equivalent diameter,

d.., =
_ li (p? - 0.907 (6.32)
do

1.1
(31.75 - 0.907 x 25.4 ) = 18.3147 mm
25.4
Shell side Reynolds number:
deGs 0.018 3147 x1052.89
Process Engineering Channel

Re = = 38 566.7
Po 0.5x10 -3
Prandtl number:

CpoPo 2.95 x 0.5 xlO"3 xlO3

Pr = = 14.75
0.1

/ \0.14
@ProcessEng

0 55 033 P
^ = 0.36 Re " Pr (6.35)
K.. V Pw J

0.36x0.1 n„ n„
h„ = x (38 566.7) x (14.75)a33
0.018 3147
h0 = 1590.82 W/(m2 • 0C)
 Introduction to Process Engineering and Design

Calculations of overall heat transfer coefficient, U0:

1 1 | I | d,, ln((j(, ldl) ^ d0 j ^dn i

(6.42)
Ug h0 liolj 2kw dj hjj dj /?,
Take thermic fluid (oil) side fouling coefficient, hod = 5000 W/(m2 • 0C) and soybean
oil side fouling coefficient, hid = 3000 W/(m2 • 0C) (Ref.: Table 6.9)
Tube material = SS 316
Thermal conductivity of tube material, kw = 16.26 W/(m2 • 0C)
(Table 3-322, of Ref. 2)

1 1 | 0.0254 ln(25.4/22.098) 25 4 1
■+ + + —x
1590.82 5000 2x16.26 22.098 3000
1
+ ^Lx
22.098 1063.87
f/() = 416.5 W/(m2 • 0C)
Heat transfer area:

1>c 236.67 xlO3

Heat transfer area required. A,. = = 6.52 m2
Uo AT,,, 416.5x87.141
A.. 6.52
:
Length of tubes required, L,. = — = = 2.403 m
N, Kd0 34 x ^ x 0.0254
Let tube length L=3m
Heat transfer area provided, A = N, n d0 L
A =34x^x0.0254x3 = 8.139 m2

8.139-6.52
% Excess heat transfer area = x 100 = 24.83 % (satisfactory)
6.52
Tube side pressure drop, A/?,:
/ \-0.14
puf
^= N * .if (Lid,) + 2.5 (6.27)

For Re = 13 673.14, Jf= 0.0045 (from Fig. (6.13))

825 xL52
Ap, = 1 8 x 0.0045 xl+ 2.5
0.022 098
Process Engineering Channel

= 6856.4 Pa = 6.856 kPa (adequate)

Shell side pressure drop, A/?v:
/ \\-0.14
L).
Ds ( r o..u:
Po". 2 u
P
Aps = 8 Jf i1' (6.40)
d
e J 2 V P'V y
For = 38 566.73 and 25 % cut segmental baffles
@ProcessEng

Jf = 0.04 (From Fig. 6.15)

,( ,
254 3i . . 710 x L4832
A/7s = 8 x 0.04 x 3 = 69 299 Pa = 69.3 kPa
ll8.3I47 U.isJ
Aps = 69.3 kPa which is (optimum) pressure drop, Aps max = 70 kPa
(Ref. Table 6.8)
 Process Design of Reactors

Resulting data for cooling:

Reacting soybean oil flow rate = 70 m Vh = 58 575 kg/h
Inlet temperature of soybean oil = 165 0C
Outlet temperature of soybean oil = 159.3180C
Flow rate of thermic fluid = 40.68 m3/h = 28 883 kg/h = 8.023 kg/s
Inlet temperature of thermic fluid = 70oC
Outlet temperature of thermic fluid = 80oC
Heat duty of cooler (HE-1). 0C = 236.67 kW
Overall heat transfer coefficient, Un = 416.5 W/(nr • 0C)
Type of heat exchanger (HE-1) = BEM Type, 1-1 shell and tube
Tube OD = 25.4 mm, 16 BWG thick
Number of tubes = 34, A pitch, p, = 31.75 mm
Tube length = 3 m
Heat transfer area = 8.139 m2 (provided)
% Excess heat transfer area = 24.83%
Shell ID = 254 mm
Baffle type = 25% cut segmental
Baffle spacing = 150 mm
Tube side pressure drop, Ap, = 6.856 kPa
Shell side pressure drop, Aps = 69.3 kPa
Heating before starling of reaction:
Let time required for heating the soybean oil from 30oC to I400C, 0=2 h = 3600 x 2
= 7200 s
The same thermic fluid (oil) will be used as heating medium. Let Tj" is the inlet tem-
perature of hot oil (thermic fluid) to heat exchanger in heating period. Both side flow
rates (shell side and tube side) for heating period can be kept same as that for cooling
period.
For heating in batch reactor by circulation through external exchanger.

mCL
In 0 (10.13)
r
v ' i ~ '2 y MCL Ki

(Eq. (10-147d) of Ref. 2)

"Tj" = temperature of heating medium at inlet, 0C
q = temperature of cold fluid at the beginning of heating period, 0C
t2 = temperature of cold fluid at the end of heating period, 0C
Process Engineering Channel

m = flow rate of cold fluid through external heat exchanger, kg/s

0 = time of heating period, s

K2= (10.14)
2 0
U = Overall heat transfer coefficient, W/(m • C)
A = heat transfer area, m2
CL = specific heat of cold fluid, kJ/(kg • 0C)
@ProcessEng

/, = 30oC, t2 = 140oC, m = 16.27 kg/s, CL = 2560 J/(kg ■ 0C)

A =8.139 m2, A/= 10 000 kg, 0 = 7200 s
U = 400 W/(m2 - 0C) (approximately same as that for cooling period)
Here, flow rates of oils are same as that for cooling period. However, small change in
the value of U can be expected due to the change in the values of thermal properties of
both oils with temperature.
 Introduction to Process Engineering and Design

UA 400x8.139
= 0.078 163
mCL 16.27x2560

K2 = = 1.0813

T| - 30 16.27 x 2560 1.0813-1

In x 7200 = 0.881
T, -140 10000x2560 1.0813

T, -30
= e,0.881 = 2.4133
IJ -140
'rx = 217.830C
Let inlet temperature of hot oil, Tx = 230oC
Outlet temperature of hot oil, ^ = 220oC
Design of cooler (HE-2) of oil cycle:
Type of heat exchanger: BEM type, Fixed tube sheet
Tube side fluid: Cooling water
Shell side fluid; Oil (thermic fluid)
Cooling water inlet temperature = 320C
Cooling water outlet temperature = 370C
Heat duty, 0= heat duty of external heat exchanger during cooling period = 236.67 kW
Cooling water flow rate,
236.67 x 103 = mCL At = m x (4.1868 x 103) (37 - 32)
m = II.3055 kg/s = 40 700 kg/h
Mean temperature difference:
ATm = LMTD x F,

(80-37)-(70-32)
LMTD = = 40.4485 0C
(80-37)
In
(70-32)

Let number of the side passes = two

T1-T2 h
R= S= (6.15)
h ~h
Process Engineering Channel

80-70 37-32
R= =2, S= =0.1042
37 - 32 80-32

F, = 0.99 (From Fig. 6.11)

ATm = 40.044 0C
Evaluation of tube side heat transfer coefficient, hf.
Let tube side velocity, u, = 1.5 m/s
Density of water at 34.50C = 994.202 kg/m3
@ProcessEng

40 700./3600
Volumetric flow rate of water = = 0.011 37 m3/s
994.202

0.01137
u, = = 1.5
a
i
 Process Design of Reactors 695

3
Hence, tube side flow area, o, = 7.58 x 10 nr = -j- x
Np =2
Let d0 = 19.05 mm, d,- = 15.748 mm

7.58 x K)"3 = — x - (0.015 748)2

2 4
= 78
From Table 6.1 (d), for 25.4 mm triangular pitch, Np = 2, Shell ID = 305 mm
di u, p 0.015 748x1.5x994.202
Re =
R 0.73 x 10
Re = 32 171.3

C./j 4.1868 x 0.73 x 10"3 xlO3

Pr = = = 4.867
k 0.628
(Viscosity of water, /j = 0.73 cP, Thermal conductivity of water, k = 0.628 W/(m ■ 0C)
/ .. \0.I4
=0.023 to08 Pr033 (6.19)
\Pw /

0 628
h: = 0.023 x - x 32 171.3a8 x 4.867 a33
0.015 748
hf = 6240.7 W/(m2 • 0C)
Evaluation of shell side heat transfer coefficient, h0:
Shell side flow area,

P, -do
As = x Ds x Bs (6.29)
Pi
Pt = 25.4 mm, d0 = 19.05 mm, Ds = 305 mm
Let Bs = 125 mm
25.4-19.05 , ,
A, = x 0.305 x 0.125 = 9.531 25 x lO-3 m2
25.4
m
o
Shell side mass velocity, Gs = (6.30)
4
Process Engineering Channel

G = = 841.757 kg/(m2 • s)
9.53125 x 10

us = {GJp0) = (841.757/710) = 1.1856 m/s

Shell side equivalent diameter,

d
e=^r (42-0.907 J2) (6.32)
d
o
@ProcessEng

d,e = (25.42 - 0.907 x 19.052)

19.05
de = 18.25 mm
deG. 0.018 25x841.757
Re = — = = 30 724
P 0.5 x 10
Pr = 14.75
 Introduction to Process Engineering and Design

0.14
k1
— "/V ' (6.35)
k

0.36x0.1 n „
hn = x (30 724)
x (14.75)
0
0.01825
h0 = 1408.8 W/(m2 • 0C)
Evaluation of overall heat transfer coefficient. U0\

1 1 | j | d0\n{dnldi) ^ dn [ ^ d0 !
(6.42)
U
o K hod 2 kw di hid di ^
Thermic fluid (oil) side fouling coefficient, hnd = 5000 W/(m2 ■ 0C)
Tube material = mild steel
kw = 50 W/(m • 0C)

1 1 + i + 0.019 05 ln(19.05/15.748)
U. 1408.8 5000 2x50

19.05
1 19.05 1
+ + xx
15.748
5000 15.748 6240.7
2
V0 = 723.66 W/(m ■ 0C)
Heat transfer area required,

<P 236.67 xlO3

A = = 8.167 m2
U0 A'Tm 723.66 x 40.044
8.167
:
Tube length required, L.. = = 1.7495 m
78x^x0.019 05
Let tube length, L = 2 m
Heat transfer area, A = /Vf ;r ^ L = 78 x ttx 0.019 05 x 2 = 9.336 m2
9.336-8.167
Excess heat transfer area = x 100= 14.31 % (adequate)
8.167
Tube side pressure drop, Ap,:

M = Np 8 7/ (L/di) A + 2.5 (6.27)

For Re = 32 171.3, Jf= 3.5 x 10"3 from Fig. 6.13

Process Engineering Channel

( 2000 ^ 994.202 x 1.5^

Apr = 2 x 8x3.5x10i-3 x 1 + 2.5
115.7487
15.7487
Ap, = 13 547 Pas 13.547 kPa (adequate)
Shell side pressure drop, APS:
,-0.14
Ps"s ( P Y
@ProcessEng

AP, = 8 7,- (6.40)

U J U.,J 2 UnJ
For Re = 30 724, Jf= 0.041 from Fig. 6.15 for 25% baffle cut
2
f2000NI 710 x 1.203
Ap, = 8 x 0.041 f 305 1 x 1
118.25 j I 125 y 2
= 45 060 Pa = 45.06 kPa (adequate)
 Process Design of Reactors 697 |

Resulting data for oil cooler (HE-2) of oil cycle:

Shell side fluid = Oil (thermic fluid), In = 80oC, Out = 70oC
Tube side fluid = Cooling water. In = 320C, Out = 370C
Heat duty = 236.67 kW
Mean temperature difference = 40.044oC
Overall heat transfer coefficient = 723.66 W/(nr • 0C)
Heat transfer area required = 6.873 m2
Heat transfer area provided = 9.336 nr
% Excess heat transfer area = 14.31 %
Tube OD = 19.05 mm, Tube ID = 15.748 mm, Tube nos. = 78
Tube length = 2 m, nos. of tube side passes = 2
Heat exchanger type = BEM as per TEMA
MOC of heat exchanger = Mild steel
Shell ID = 254 mm
Tubeside pressure drop = 13.547 kPa
Shell side pressure drop = 37.525 kPa
Note: Circulation rate of soybean oil is fixed at 71 m Vh. However, differential pres-
sure (DP1C) is unknown. It will depend on desired hydrogen circulation rate in the
reactor. To begin with DP = 3 bar may be fixed and by actual experience this can be
optimized. Reactor pressure and differential pressure together will decide discharge
pressure and power requirement of the gear pump.

10.7 BUBBLE COLUMN REACTOR8 9

In a bubble column reactor, gas is dispersed in liquid phase at the bottom of

column by a suitable distributor. In most of the cases this distributor is a sparger.
Bubble column can be operated in a semibatch, countercurrenl or cocurrent man-
ner. Bubble columns are used as reactors, absorbers and strippers.

Gas Exit

p£c]—>- Liquid Outlet

Process Engineering Channel

Cooling Medium Out

Cooling Medium In >-IXH-

@ProcessEng

Fig. 10.7 Bubble Column Reactor

 Introduction to Process Engineering and Design

Bubble column reactor is preferred for slow or very slow gas-liquid reactions.
As overall rate of this reaction is governed by rate of chemical reaction, the rate
of consumption of limiting reactant in chemical reaction (-dNA/dt) is directly
proportional to Vj (volume of liquid phase inside the reactor or liquid holdup).
Rale of consumption of limiting reactant in reaction (-dNA/dt), in case of slow or
very slow reaction, does not depend on interfacial surface area of contact be-
tween gas and liquid phase.
Bubble column reactor does not use any moving part like agitator. Construc-
tion of this reactor is simple and inexpensive.

10.7.1 Various Factors Affecting the Performance of

Bubble Column Reactor

(i) Superficial Gas Velocity

Increase in superficial gas velocity increases gas holdup, the effective interfacial
area and the overall mass transfer rate. Increase in superficial gas velocity decreases
the size of bubbles hence increases the interfacial area of contact between gas
and liquid. Effect of superficial gas velocity is negligible on mass transfer
coefficient (KL) but significant on mass transfer area (a). For chemical reaction
controlled gas-liquid reaction (slow or very slow gas-liquid reaction) also, certain
minimum KLa must be achieved to overcome the effect of mass transfer. It is
recommended to keep superficial velocity of gas less than or equal to 10 m/s.

(ii) Properties of Gas Phase and Liquid Phase

Physical properties of gas phase have no effect on the performance of the column.
However, the physical properties of liquid phase like surface tension, viscosity,
etc., have a profound effect on the performance of column. Increase in the viscosity
of liquid phase or decrease in the surface tension increases the effective interfacial
area and hence increases mass transfer rate. Presence of electrolyte in the liquid
phase effects greatly on performance. The electrolyte solution gives smaller bubble
size and consequently higher effective interfacial area and higher rate of mass
transfer.

(Hi) Back Mixing

Process Engineering Channel

Based on a study, it is found that gas flows in bubble column operates in plug
flow manner without any back mixing while considerable amount of back mix-
ing in the liquid phase is observed.
Back mixing in liquid phase decreases the concentration of liquid reactant and
hence the rate of chemical reaction. Consequently it decreases the overall rate of
reaction. Use of packings, trays or baffles reduces liquid back mixing and thereby
@ProcessEng

reduces dilution of reactants by products. Hence, they provide the higher concen-
tration of reactant and hence the higher rate of chemical reaction, -rA = (-1/V/)
(-dNA/dO). But they decrease the liquid holdup (V/). Hence, combined effect on
rate of consumption of limiting reactant in reaction (-dNA/d6) must be checked
before using any internal in the bubble column. In case of highly exothermic
gas-liquid reaction, back mixing in liquid phase is desirable to control the
exotherimicity of reaction or to control the temperature of reaction. In such a
 Process Design of Reactors

case placing packings to improve the overall rate makes the temperature control
very difficult because it increases the heat duty required and decreases heat trans-
fer coefficient.

(iv) Alode of Operation

For very slow gas-liquid reaction, semibatch operation is preferred in which liquid
is charged to the reactor in batchwise manner while gas is continuously passed
through the column. For moderately fast reaction, continuous operation is
preferred. Both counter current and cocurrent operation is used. But cocurrent is
more common. In counter current contact, velocities of gas and liquid through
the tower are limited by flooding conditions while cocurrent contact permits the
higher velocities of gas and liquid through the tower compared to counter current
contact. Also, concentration of reactants, rate of chemical reaction and overall
rate of reaction do not depend on the mode of operation (whether it is cocurrent
or counter current) becuase bubble column reactors are ideal mixed flow reactors.
If superficial liquid velocity is greater than 30 cm/s and superficial gas veloc-
ity is less than 1 to 3 cm/s then it is better to use cocurrent down flow column.
(Ref.: 8)

(v) Gas Expansion and Shrinkage

Inside the bubble column, there may be a dramatic increase in superficial velocity
of gas from gas inlet to outlet and is called gas expansion. Decrease in superficial
velocity of gas from inlet to outlet is called gas shrinkage.
Example of gas expansion:
Chlorination of benzene gives chlorobenzene and hydrogen chloride gas. In this
case theoretically total number of moles of gas phase remains constant and hence
flow rate of gas and superficial velocity of gas remains unchanged. But actually
this reaction is exothermic, resulting in vaporization of organic liquids. Hydro-
gen chloride and unconverted chlorine, leaving from the top, are saturated with
organic vapours at the outlet conditions. In addition to that hydrostatic head of
liquid decreases in upper part of column. Because of these combined effects,
there is a considerable increase in superficial velocity of gas from inlet to outlet.
Example of gas shrinkage:
Process Engineering Channel

Alkylation of benzene with ethylene in presence of AICI3 (aluminium chloride)

solution as catalyst. Because of the consumption of gas (ethylene) in the reac-
tion, there is a substantial decrease in superficial velocity of gas in upper part of
column.
Since superficial gas velocity affects overall reaction rate, mass transfer rate
and heat transfer rate, this factor is important and should be carefully considered
in designing of bubble column reactor.
@ProcessEng

(vi) Pulsation

The performance of bubble column can be improved by pulsations. For very low
superficial velocity of gas (0.8 to 2.4 cm/s) the value of KLa can be increased by
factor as much as 3 by pulsation.
 Introduction to Process Engineering and Design

(vii) Addition of Packing or Packed Bubble Column

Adding packing reduces axial mixing of liquid. Hence, packed bubble column is
used where liquid back mixing is undesirable. For gas-liquid reaction in which
substantial gas shrinkage is taking place in the reactor due to reaction, this results
in very low superficial gas velocity which in turn results in poor rate of mass
transfer in the upper part of reactor. Hence, in such a case placing of packings in
upper part is beneficial. Packing increases effective interfacial area and gas hold-
up to an extent. Hence, it provides higher rate of mass transfer. Packed bubble
column is not used if fine solid particles are present in the system as catalyst or as
reactant. Packing is also not preferred for highly exothermtic or endothermic
reaction as packed tower provides poor heat transfer coefficient.

10.7.2 Industrial Examples of Bubble Column Reactor

(i) Production of protein from methanol is carried out in a fermentor which are
bubble column reactors. Largest size of bubble column reactor having
capacity of 3000 m3 is used for this application. (Ref: 3)
(ii) Absorption of carbon dioxide in ammoniated brine for the manufacture of
soda ash.
(iii) Liquid phase air oxidation of a variety of organic compounds.
Ex. (a) Air oxidation of acetaldehyde in presence of fine KMnC^ (potas-
sium permenganate) particles as catalyst (b) Air oxidation of p-nitrotoluene
sulphonic acid
(iv) Air oxidation of black liqour containing I^S (sodium sulphide) in pulp (in
a paper mill)
(v) Air oxidation of ammonium sulphide [(NH^S]
(vi) Liquid phase chlorination of variety of organic compounds. Ex. (a) Chlo-
rination of benzene to chlorobenzene (b) Chlorination of acetic acid to
monochloroacetic acid, etc.
(vii) (a) Carbonylation of methanol to acetic acid.
(b) Carbonylation of ethanol to propionic acid
(viii) Liquid phase oxychlorinalion of ethylene for the production of vinyl chloride
(ix) Hydration of propylene with sulphuric acid for the production of vinyl
Process Engineering Channel

chloride
(x) Reaction between ethylene (C2H2) and liquid hydrogen fluoride for the
manufacture of ditluoroethane.

10.7.3 Advantages and Disadvantages of Bubble Column

Reactor Over Stirred Tank Reactor (Agitated
@ProcessEng

Vessel Type Reactor)

(a) Advantages
(i) Sealing problem is negligible in bubble column while the same is severe in
agitated vessel type reactor. Sealing of the shaft of an agitator for high
pressure reactor is not only an initial design problem but also a continuing
maintenance problem. This problem is very important for highly toxic, high
 Process Design of Reactors

pressure reaction system, e.g. ozonation reaction. Above 40 atm operating

pressure, agitated vessel type reactor is not recommended for use.
(ii) Bubble column reactor provides more liquid hold-up than agitated vessel
type reactor. Hence, it requires less volume for chemical reaction control-
led gas-liquid reaction (for slow and very slow gas-liquid reaction).
(iii) Bubble column reactor requires less maintenance as compared to agitated
vessel type reactor.
(iv) Bubble column reactor requires less power consumption. Because of the
agitator, power consumption is higher with agitated vessel type reactor.
(v) It requires lesser floor space.
(b) Disadvantages
(i) Agitated vessel type reactor provides higher mass transfer coefficient. Hence,
for mass transfer controlled gas - liquid reaction, agitated vessel type reac-
tor requires lesser volume for the given extent of reaction. It may require
lesser fixed capital investment than bubble column reactor for such appli-
cations.
(ii) Agitated vessel type reactor provides higher heat transfer coefficient com-
pared to bubble column reactor. Hence temperature control is easier with
agitated vessel type reactor than the same for bubble column reactor.
(iii) Higher interfacial area is obtained with agitated vessel type reactor. Agita-
tor cuts the bubbles in smaller sizes and thereby increases interfacial area
of contact. Higher interfacial area provides higher mass transfer rate.
(iv) Bubble column reactor requires more height.

10.7.4 Criteria of Selection for Different Types of Gas-Liquid

Reactors

Table 10.9 Typical Ratios for Gas-Liquid Reactors (Ref: I)

Type of reactor S/V, S/V, v,ivR W,im

Packed column 1200 100 0.08 10 to 100
Tray tower 1000 150 0.15 40 to 100
Agitated vessel 200 200 0.9 150 to 800
Process Engineering Channel

Bubble Column 20 20 0.98 4000 to 100 00

where, S = Interfacial surface area, nr

V/ = Volume of liquid, m3
VR = Volume of reactor, m3
Vfilm = Volume of liquid film, m
Overall rate of any gas - liquid reaction is a function of rate of chemical reac-
@ProcessEng

tion and rate of mass transfer. [Overall rate =/(Rate of chemical reaction, rate of
mass transfer)].
For very fast reaction overall rate of reaction is governed by rate of mass trans-
fer, i.e. rate of chemical reaction » rate of mass transfer or
Overall rate of reaction = Rate of mass transfer.
 Introduction to Process Engineering and Design

To get the higher rate of mass transfer, packed tower is the best choice. Packed
tower provides higher mass transfer coefficient as well as higher interfacial area
of contact. But packed bed provides poor heat transfer coefficient.
For slow and very slow gas liquid reaction overall rate is governed by rate of
chemical reaction. Rate of consumtion of reactant in a chemical reaction does not
depend on interfacial area of contact (S), but it depends on liquid holdup Vf,

'-Ma]
——— = VjkfiC). Bubble column reactor provides maximum liquid holdup.
du y
V/Vfl ratio is maximum for bubble column reactor while the same is very low for
packed bed reactor. Bubble column reactor provides low heat transfer coeffi-
cient.
For the gas-liquid reactions having intermediate rates, overall rate of reaction
depends on both; rate of chemical reaction and rate of mass transfer. Hence, for
these reactions agitated vessel type reactor is the best choice, because it provides
higher SIVR ratio and higher ratio. It provides higher heat transfer coefficient
but it consumes more power. For high pressure gas-liquid reaction if gaseous
reactant is toxic then bubble column reactor is preferred against agitated vessel
type reactor because of the sealing problem. Example: Carbonylation of methanol
gives acetic acid. It is a intermediate gas-liquid reaction. Agitated vessel type
reactor is the best choice. But, operating pressure of reactor is 50 atm and carbon
monoxide is a toxic gas. So, to avoid the use of agitator shaft sealing, for the
same reaction, bubble column reactor is preferred.
For highly exothermic gas-liquid reaction, loop reactor or jet reactor (with
recirculation, recirculating pump and external heat exchanger) can be considered.
Loop reactor provides higher heat transfer coefficient and hence better temperature
control than bubble column reactor. But, it consumes more power. For
hydrogenation of edible and non-edible oils, loop reactor or jet reactor or gas
induced agitated reactor is found to be an excellent choice as it gives desired
product pattern in less time than an agitated type batch reactor with sparger
mechanism.

10.7.5 Process Design of Bubble Column Reactor

Process Engineering Channel

It can be divided in following steps.

(i) Find the working volume of reactor. Working volume of reactor means vol-
ume of liquid in reactor in running condition which also includes gas holdup.
Bubble column reactors are selected for slow or very slow gas-liquid
reaction for which overall rate of reaction is totally controlled by the rate of
chemical reaction. Hence, with most of the bubble column reactors (bubble
column reactors are used for different applications), it is very easy to over-
@ProcessEng

come the effect of mass transfer. Superficial velocity of gas in bubble col-
umn reactor is fixed in such a way that effect of KLa or mass transfer is
eliminated. If the superficial velocity of the gas is fixed above the limiting
value then overall rate of gas-liquid reaction is equal to the rate of
chemical reaction. Sgm is the minimum superficial velocity of gas required
to overcome the effect of mass transfer.
 Process Design of Reactors

For example,
y4(g) + b B{{) —> Product

dNA
If 5? » Sgm Overall rate = -rAl = = k CA CB
V/ dO

In bubble column reactor, liquid is flowing in mixed flow manner. Hence,

composition of reactants in liquid phase is almost uniform throughout and
working volume of reactor can be determined by using the performance
equation of ideal mixed flow reactor.

V,
(10.15)
FAo -r.Al

If for the given gas-liquid reaction it is not possible to overcome the effect
of mass transfer, then form of overall rate of gas-liquid reaction must be
developed. It can be developed by laboratory scale and pilot plant scale
experiments. Different forms of rate equation are asssumed and then veri-
fied by experimental data. In such a case overall rate is the function of both
mass transfer coefficient {KLa) and reaction rate constant k.
For example, for the gas-liquid reaction
A(g) + B(I) —> Product,
following form of rate equation can be asusmed for verification.

1 dN, Pa Cl
r
- A = (Typical)
V, dt 1 1
+ +

Ktci kCB K, a kCB

where, = Mass transfer coefficient

a = Interfacial area per unit volume
k = Reaction rate constant
Ha = Henry's law constant
pA = Partial pressure of reactant A in gas phase
= Concentration of reactant A in liquid phase
In such a case also, since in bubble column reactor liquid phase is flowing
Process Engineering Channel

in mixed flow manner, working volume V/ can be determined by following

equation.

V. XA
(10.16)
FAo -rA

where, - rA = Overall rate of reaction = f(KLa, k)

@ProcessEng

(ii) Find or fix the value of superficial velocity of gas. Superficial velocity of
gas in bubble column reactor should be such that overall rate of reaction
becomes independent of mass transfer coefficient KLa. Minimum superfi-
cial velocity of gas required to overcome the effect of mass transfer should
be determined by actual experiment in small scale (labscale or pilot plant
 Introduction to Process Engineering and Design

reactor). Many different correlations are available which relate the superfi-
cial velocity of gas and mass transfer coefficients; KLa. However, they are
not reliable and change from system to system. If it is not possible to over-
come the effect of mass transfer, then correlation of KLa must be developed
in small scale reactor for the given system and the same can be used to
determine the diameter of commercial reactor. In scale - up, influence of
wall effect (which is significant in small scale reactor while it is negligible
in commercial scale reactor) must be considered.

2
D[
—D = —
- (10.17)
4 ' 58

where, Qv = Volumetric flow rate of gas, m3/s

Z)( = Inside diameter of reactor, m
= Superficial velocity of gas, m/s
Based on the value of D(, height of reactor H can be detemined.
(iii) Calculate the heat transfer area required:
Heat duty required for bubble column reactor can be determined from the
heat of reaction AHR at reaction temperature.

lOOOmol kmol
0, = AHr kJ/mol x x of limiting reactant
1 kmol h

consumed ± <p'
where, 0' = Heat utilized for other purpose

/
Pr
' w
0.22
hj = 21 766.5 S (10.18)
8
Pri
where, hj = Reacting fluid side heat transfer coefficient, W/(nr • C)
SH = Superficial velocity of gas, m/s
Prw = Prandtl number of water at room temperature
PrL = Prandtl number of liquid phase of reactor at reaction
condition.
(iv) Sparger design is not important if superficial gas velocity is more than or
Process Engineering Channel

equal to 10 cm/s.

Example 10.6
In the continuous process for the manufacturing of monochloroacetic acid (MCA) con-
version of acetic acid is restricted to 50% to avoid the formation of dichloroacetic acid.
Reaction is carried out in a bubble column reactor.
Determine the following.
@ProcessEng

(a) Working volume of reactor

(b) Diameter of reactor
(c) Height of liquid inside the reactor during reaction
(d) Heat duty of over head condenser in which exist gas-vapour mixture is cooled
down to 40oC by cooling with water
(e) Heat transfer area required for bubble column reactor
 Process Design of Reactors

Data
(i) Reaction
CH.COOH,,, + Cl2(g) I00CC ) CH2 CICOOH(l) + HCl(g)
(ii) Heat of reaction at reaction temperature, i.e. at I00oC
AHr = -87.92 kJ/mol (Exothermic)
(iii) 20% excess chlorine is used.
(iv) Cooling water is available in plant at 320C.
(v) Mass transfer coefficient data
.-i
Sg = 1 to 30 cm/s KLa = 0.25 x 10"2 to 0.4 s
(vi) Rate of chemical reaction

1 dNA i-5 „-l

= kCA, k = 2.777 x lO^s
rA
V, dt
Density of acetic acid, p = 1048 kg/m3
(vii) Production rate of monochloroacetic acid = 1 t/h
(viii) Operating pressure in reactor = 0.1 atm g
Solution:
(a) Working volume of reactor
Bubble column reactor can be assumed as ideal mixed flow reactor.

^1
(10.15)
Pao -rA

XA Xa 1 0.5
x
1

Pao KCa kCAo (\-xA) kCAo (1-0.5)

[Pao^ I _Vo
II

Sao J k k

where, V0 = Volumetric flow rate of acetic acid at inlet

Stoichiometric equation:
CHjCOOH,,) + Cl2(g) = CH2CICOOH(1) + HCl(g)
60 71 94.5 36.5
Conversion of acetic acid is restricted to 50% to avoid the DCA formation.
Process Engineering Channel

Acetic acid required to produce 1 t/h of MCA:

mAA = 1000X -60_x-L

94.5 0.5
mAA = 1269.84 kg/h

1269,84 =12117m3/h

1048
@ProcessEng

,-44 m
V0 = 3.3658 x 10- _3/
Vs

V0 3.3658x10,-4
V,= = 12.12 m3
T 2.777x10 -5

Working volume of reactor, V, = 12.12 m3 Ans. (a)

 Introduction to Process Engineering and Design

(b) for superficial velocity of gas

e {1 cm/s, ...,30 cm/s), KLa » k (as given in data)
Let = 10 cm/s, KLa » k
Overall rate of reaction = Rate of chemical reaction
Mass flow rate of chlorine at inlet

mci =1.2x x 1000

2
94.5
riiQ^ = 901.59 kg/h
Density of chlorine gas

pM 1.1x71 273 •,
1
pcl 2 = = x = 2.55 kg/m
RT (273 + 100) 1x22.414

901 59 ^ i
Volumetric flow rate of chlorine = " " = 353.56 m/h = 0.098 21 m3/s
2.55

K . Qv
-Df = — (10.17)
4 -v,

—D2 = aQ9821 =0.9821 m2

4 lOx 1

100,

D( = 1.118 m Ans. (b)

(c) Let hL = Height of liquid during reaction

Vit = -Dfh
4 ' LL

12.12 = - (L118)2 x h,
4
hL = 12.346 m
Minimum distance required to facilitate gas-liquid separation is recommended to
be Dr
Let H = height of bubble column reactor = hL + Di
Process Engineering Channel

H= 12.346+ 1.118 = 13.464 m

Let 77= 14 m Ans. (c)
(d) Let = Heat duty of overhead condenser
In over head condenser gas-vapour mixture is cooled down to 40oC.
Let h, = Total molar flow rate of gas-vapour mixture leaving the reactor.
Exist gas from the reactor is saturated with liquid vapour at outlet conditions of the
reactor. Molar flow rate of chlorine at outlet of reactor
@ProcessEng

hn
Cl2
= 0.2 x = 2.116 kmol/h
94.5
Molar flow rate of hydrogen chloride gas at outlet of reactor

nHri = = 10.582 kmol/h

HC1
94.5
 Process Design of Reactors

n, - "ci2 + "hci + nAA + hMCA

and pr = pC|2 + pnci + Paa + Pmca

Pt = Pc\2 + P\\C\ + PvAA X XAA + XMCA X PvMCA

At l()0oC vapour pressure of acetic acid pVAA = 400 torr
At 100oC vapour pressure of MCA, pVMCA = 30 torr
p,- 1.1 x 760 = Pc\2 + Phci + 400 x 0.5 + 30 x 0.5 = 836 torr

Pc\2 + Phci = 621 torr

(Pc\2 + Phc\ yP, = ("hci + "ci2 )l'h

621 10.582 + 2.1164

836 ht

h, = 17.095 kmol/h
o
At 100 C or in the exist gas - vapour mixture from the reactor

400 x 0.5
hAA = x 17.095 = 4.09 kmol/h
^ 836

30x0.5
11 x
mca- 17.095 = 0.307 kmol/h
836
This gas-vapour mixture is cooled to 40oC by cooling water in the overhead con-
denser. At outlet of the overhead condenser, gas mixture is saturated with acetic acid and
MCA vapour.
To find out the composition of gas-vapour mixture at the outlet of overhead con-
denser, for the Is1 trial calculations assume that almost total condensation is taking place
in condenser.
Condensate composition at outlet of condenser

4.09 n na
^aa = = 0.93
4.09 + 0.307
X
MCA = 0-07
o
At 40 C, P,' =P,-&PHE
p' = 1.1 -0.04= 1.06 atm
The pressure drop in heat exchanger for gas-vapour mixture is assumed to be 0.04 atm.
Process Engineering Channel

At 40oC or at outlet of overhead condenser

+
//, = 1.06 x 760 = /'hci /'ci2 + 0.93 x pVAA + 0.07 x pVMCA
At 40oC, pvAA = 38 torr, pvMCA = I torr

805.6 = Phci + Pc\2 + 0.93 x 38 + 0.07 x 1

Phc\ + Pc\2 = 770.19 torr

@ProcessEng

Phci + Pc\2 10.582 + 2.1164 770.19

pt' ht 805.6
ht = 13.28 kmol/h
o 1 torr
At 40 C, PVAA = 38 torr, PVMca =
 708 Introduction to Process Engineering and Design

0.93x38x13.28
hAA = = 0.5826 kmol/h
805.6

0.07 x 1
x 13.28= 1.154 x 10_3 kmol/h
MCA
805.6
For 2 trial calculations, composition of condensate at outlet of overhead condenser is
calculated.

4.09-0.5826
= — =0.9198
(4.09 - 0.5826) + (0.307 -1.154 x 10-3)
X = _X =
MCA ' AA 0-0802
pr = 805.6 = Phci + Pci2 + 0.9198 xpVAA + 0.0802 x pvMCA
805.6 = pHa + pcli + 0.9198 x 38 + 0.0802 x 1
=
Phci + Pci, 770.5674 torr
+
Phci Pci, 10.582 + 2.1164
L. = 0.9565 =
n
Pr i
h, = 13.276 kmol/h
0.9198x38x13.276
nAA = = 0.576 kmol/h
^ 805.6
0.0802 x 1
n = x 13.276 = 1.32 x K)"3 kmol/h
MCA
805.6
For the new values of nAA and nMCA
x
aa =0.919 97, %CA = 0.08 or ^ = 0.92, a:,WC/1 = 0.08
These values are very close to previous values. Hence, third trial is not required.
Mass of acetic acid condensed = (4.09 - 0.576) x 60 = 210.84 kg/h
Mass of MCA condensed = (0.307 - 1.32 x lO"3) x 94.5 = 28.887 kg/h
Heat duty of overhead condenser
= Sensible heat transfer of gas-vapour mixture + Latent heat transfer
for condensation of vapours + Subcooling of condensate
(Subcooling of condensate from inlet to outlet temperature is neces-
sary in multicomponent condensation.)
Process Engineering Channel

< {m
t>,c= c\2 Cp,c\2 + '"MCI Cp,hci +m'AA Cp,AA + m^cA Cp,MCA) AT
m
+ AA IAA + mMCA ^MCA + (mAA CLAA + m^CA CLMCA) AT

where, mc/, = 2.1164 x 71 = 150.26 kg/h

mHCI = 10.582 x 36.5 = 386.24 kg/h

@ProcessEng

4.09 + 0.576
mAA = x 60 = 139.98 kg/h
2

0.307 +1.32 xlO-3

"imca = x 94.5 = 14.568 kg/h
 Process Design of Reactors 709 [

Table 10.10 Specific Heat of Gases/Vapours Vapours and Liquids at 70°C

Component Cpi, kJ/(kg • 0C) CLi, kJ/(kg • 0C)

Chlorine 0.5024 —
Hydrogen chloride 0.7955 —
Acetic acid 1.2267 2.22
MCA 1.0467 1.9

mAA = 210.84 kg/h, mMCA = 28.887 kg/h

?iAA = HO kcal/kg = 460.55 kJ/kg at 70oC temperature
=
XMca kcal/kg = 355.88 kJ/kg at 70oC temperature
0 + 210.84
mAA = = 105.42 kg/h

0 + 28.887
m
MCA = = 14.44 kg/h

(t),c = (150.26 x 0.5024 + 386.24 x 0.7955 + 139.98 x 1.2267 + 14.568

x 1.0467) x (100 - 40) + 210.84 x 460.55 + 28.887 x 355.88
+ (105.42 x 2.22 + 14.44 xl.9) x (100 - 40)
(f),c = 157 253.15 kJ/h = 43.6814 kW (Ans. (d))
(e) Heat transfer area required for bubble column reactor:
Energy balance around reactor
Heat must be removed by cooling medium circulated through the jacket around reactor
0, = Heat produced during reaction - Heat removed in overhead condenser

_ gy 92 _kJ_ x i Qoo mol ^ kmol ^cetjc consumed - 157 253.15

mol kmol h
= 87.92 x 1000 x 10.582 011 - 157 253.15
= 773 117.2 kJ/h = 214.75 kW
Let outlet temperature of cooling water from heat exchanger = 40oC

773 117.22
Mass flow rate of cooling water, mw =
4.1868x8
mw = 23 082 kg/h = 23.1 m3/h
Process Engineering Channel

If cooling water is circulated through plain jacket then jacket side heat transfer coef-
ficient can be calculated by considering plain jacket as outside pipe of double pipe heat
exchanger.
ho-
i j / \0I4
R
—-—— = 0.023 Re™ /Vl/3 (10.19)
@ProcessEng

K V Rw /
where, de = Equivalent diameter = 4x rH (10.20)

Cross sectional area

r
H=
Wetted perimeter
 710 Introduction to Process Engineering and Design

rH = — (10.21)
Ttid^+di)
=
where, Inside diameter of jacket, m
dl = Outside diameter of reactor shell, m

df d^
r
H
4
Let d2-d\ = 100 mm
de = ArH = - r// = 0.10 m

d G
Re = -—

23100/3600
G=
(n/4)(d;-d;)

dl = Reactor inside diameter + 2 x thickness of shell (rj

Let thickness of reactor shell, ts = 8 mm (assumption)
This thickness is actually determined based on mechanical design of shell.
dl = 1118 + 2x8= 1134
d2 = 1134+ 100= 1234 mm

23100/3600
G= — = 34.50 kg/(m • s)
(^"/4)(1.234 -1.134 )

0.1x34.50
Re = — = 4792 (Viscosity of water at 360C = 0.72 mPa • s)
0.72 x 10

CLn 4.1868 x (0.72 xl0_3)103

Pr =
k 0.6228
= 4.84
Process Engineering Channel

Q 6228
h = 0.023 x - x (4792)<)-8x (4.84)i/3
0.1
^ =213.19 W/(m2 • 0C)
Value of hn is very low. To improve or to increase its value, let outlet temperature of
cooling water = 340C

773117
mw = = 92 328 kg/h
@ProcessEng

" 4.1868x2

92328
G = 34.5 x = 137.9 kg/(m2 ■ s)
23100
 Process Design of Reactors 711

deG 92 328
Re = = 4792 x = 19153
^ 23100

h. = 213.18 x [ 19153"l = ^ 84 w/(m2. oq

V 4792 )
h-r
Reacting fluid side heat transfer coefficient

'Prw ^
hj = 21 766.5 5°-22 (10.18)
\ Pr,l y
where, o = Superficial velocity of gas, m/s
s., = 10 cm/s = 0.1 m/s

P'-L =

Where CL, iiL and kL are the properties of liquid phase of reactor at l00oC, temperature
(Reaction temperature).

Table 10.1 I Properties at 100oC

Acetic acid MCA Water

Q, kJ/(kg.0C) 2.3 1.884 4.1868
p. mPa • s 0.49 0.55 0.28
k, W/(m • 0C) 0.173 0.143 0.68

C/'-'mix = X w-' CLA

u

0.5x60
wAA = = 0.3883
(0.5x60)+ (0.5x94.5)
w
mca = l-wM = 0.6117
Q = I Cu Wj = 0.6117 x 1.884 + 0.3883 x 2.3 = 2.046 kJ/(kg • 0C)
W
1 = 1 _ "Tm | MCA _ 0.6117 | 0.3883
Process Engineering Channel

Hl P mix Paa Pmca 0.55 0.49

liL = 0.525 mPa ■ s
kL=l kj Wj = 0.3883 x 0.173 + 0.6117 x 0.143
kL = 0.1546 W/(m • 0C)

2.046 x 0.525 xl O-3 looo

P ri — x
@ProcessEng

0.1546
PrL = 6.9479
Prandtl number of water at 100oC:

4.1868 x 0.28 xlO-3 m3

Prw = x —
V
0.68 1
 Introduction to Process Engineering and Design

Prw = 1.724
1/2
1.724
/i,- = 21 766.5 x (0.1) 0.22 X
6.9479 J
2 0
h, = 6533.27 W/(m • C)
For MCA reactor, lead lined vessel is normally used. Let thickness of lead lining = 5 mm

= OD of lead lining = 1.118m

d? = ID of lead lining = 1.108 m

o
At 100 C, A:lead = 34 W/(m • 0C),
/W, = 45 W/(m • 0C)
Conductive resistance offered by lead lining

C Ax d, do {dp- d{)l2
—x x In x
Head ido-d-) v d'
' / ^lead

d0 In {d', Id',)

2 ^lead
Overall heat transfer coefficient U0 is calculated by following equation.

1 1 | j | d0 In {dn Id j) | djnld^/d,') ^ d0 [ ^ dn {

U
o K Kd 2kws 2 klead d, h, di hid
(6.42)
Let fouling coefficients
h. = h:d = 5000W/(m ■ 0C)

1.134 1.118
1.134 In 1.134 In
1 1 1.118 1.108
+ + +
U,. 645.84 5000 2x45 2x34

1.134 1 1.134 1
+ x ■+ x = 410.07 W/(m2 • 0C)
1.108 6533.27 1.108 5000

(100 - 32)-(100 - 34)

Process Engineering Channel

= A'4 = = 66.995 0C
' 100- 32N
In
\ 100-34

1 1000
800 000 x x
3600
A. = 8.089 m2
@ProcessEng

"req U0ATm 410.07x66.995

Let A0avai = 8-()89 x 1 -2 = 9.707 nr (Area provided)

A= 9.707 nr = Ttdo L' = kx (1.134) L'
where, L' = Length of cylinder that must be covered by jacket = 2.725 m
 Process Design of Reactors

However, entire height of liquid pool (hL = 12.346 m) must be covered by plain jacket
as shown in Fig. 10.8 to keep the uniform temperature of entire liquid pool. Reaction
temperature can be controlled by controlling the flow rate of cooling water as shown in
Fig. 10.8.

Exit Gas Mixture

CWR

D. D = 1.118 m
h, = 12.346 m

CWS KX3
FC
V V V — Chlorine Inlet

FC
Acetic Acid Inlet

Fig. 10.8 Proposed MCA Reactor Design

Use of spirals in the plain jacket decreases flow area considerably, increases
velocity and Re of jacket side fluid and consequently increases jacket side heat
transfer coefficient considerably. In this case flow area for jacket side fluid is
area between two successive metal strips which forms the spiral. (Refer
Fig. 10.9(c))
For the exothermic reaction (e.g. chlorination of acetic acid) saturated steam is
Process Engineering Channel

fed into the jacket to start the reaction but then after cooling water is circulated
through the same jacket to remove the heat of reaction. For such a case plain
jacket is selected as it is preferred for saturated steam. For cooling water circula-
tion or hot oil circulation spiral jacket, channel jacket, limpet coil, etc. provide
considerably higher heat transfer coefficient. Refer Fig. 10.9 for common ar-
rangement of jackets, limpet coil and internal coils.
@ProcessEng

10.8 DESIGN OF FIXED CATALYST BED REACTORS

FOR GASEOUS REACTIONS10 1
'•l2'2

In many syntheses, fixed bed catalytic reactors are used. Water shift reaction to
produce hydrogen by reaction of carbon monoxide with steam is carried out in a
 714 Introduction to Process Engineering and Design

Vessel Wall > -Vessel Wall

Impingement Plate —^ //

Condensing >- X
Out
Fluid
Jacket- Jacket
Jacket Width-
Heat Transfer Fluid

In
Condensate-*-
Agitating Nozzle Box

(a) Conventional Jacket (b) Conventional Jacket

(Condensing Medium) (Liquid Medium)

Vessel Wall
Out

Vessel Wall
Clearance
Out- Limpet Coil
>
(Half Coil)
Jacket
Baffle Pitch- Fleat Transfer Fluid
)
Heat Transfer Fluid

Baffle-
)

In -
-In

(c) Spiral Baffled Jacket (d) Jacket with Limpet (Half) Coil

Heat Transfer-<- Heat Transfer

Fluid Out Fluid In
Process Engineering Channel

Helical Coil

— — -< Baffles
@ProcessEng

(e) Internal Helical Coil

Fig. 10.9 (Contd.)

 Process Design of Reactors

Heat Transfer
Heat Transfer-^ Fluid In
Fluid Out

Helical Coil as Baffles

(f) Vessel with Helical Coils as Baffles

Fig. 10.9 Common Arrangements of Heat Transfer Jackets and Internal Coils

fixed catalyst bed. However, this reaction is exothermic with practically no effect
of pressure on the reaction rate. At high temperature, the rate of reaction is
relatively high but equilibrium conversion is low. In such a situation, a battery of
reactors in series is used. High temperature, medium temperature and low
temperature shift converters are common in syngas production from hydrocarbons.
Each reactor is packed with different types of catalysts. Exit gas from each
converter is passed through a heat exchanger to recover the heat and to lower the
gas temperature, entering the next reactor. In this way, advantages of high heat of
reaction at higher temperature and higher equilibrium conversion at low
temperature are achieved. In a typical natural gas based plant, carbon monoxide
content in the reformer outlet gas is about 15% (v/v) which is reduced to 0.2% (v/
v) in two or three different axial flow converters. Generally, these converters are
designed for low to moderate pressures.

Gaseous Reactants
Process Engineering Channel

Catalyst •7" '7'-- c\ VC *;

mrnmi r-i R-II R-III

@ProcessEng

Products
HE-I HE-II HE-11I
Note:
Catalysts in R-I, R-ll & R-ll could be same or of different qualities & quantities.

Fig. 10.10 Multiple Catalytic Reactors with External Heat Exchangers

 Introduction to Process Engineering and Design

For certain exothermic gaseous reactions, rate of reaction at low temperature

is so low that required volume of catalyst works out to be very large. Cost of such
a large reactor could be prohibitive, more so for high pressure reaction. Hence
certain exothermic gaseous reactions are carried out at high temperature. Exam-
ples are ammonia synthesis, methanol synthesis, dissociation of nitrous oxide to
nitrogen, etc. While designing such converters, process engineer can consider
different options. In one option, reaction is carried out in multiple reactors hav-
ing the same or different catalysts. Exit gas from each reactor is cooled in an
external heat exchanger. Partially converted gas mixture from the heat exchanger
enters the next reactor and so on as shown in Fig. 10.10.
Cost of number of reactors and heat exchangers is becoming prohibitive in
many cases. Also heat recovery from the exit gas mixture from a reactor may not
be possible in each case.
Quench bed reactors are developed for carrying out exothermic reactions at
high temperature. Figures 10.11(a) and 10.11(b) depict such designs. Entire reac-
tor is one vessel in which there are number of catalyst beds (usually 3 or 4.)
A known portion of incoming gas mixture (stream E, which is more than
50%) is introduced at the bottom at relatively low temperature. It passes through
the annulus around catalyst baskets, thereby keeping the shell of the reactor cool
and also gets some heat from the reacting gas mixture. Fj stream enters the shell
and tube heat exchanger, located at top and gets heated by outgoing gas mixture.
Hot F] stream enters 1st catalyst bed and partial conversion takes place thereby
the gas mixture is heated up. Portion of the main gas stream is so controlled that
temperature of 1st bed exit gas stream is controlled at predefined value. Partially
reacted gas mixture from 1st bed is cooled by quenching by a definite proportion
of the fresh gas mixture (1st quench). Mixing of both gas mixtures results in
lowering of the temperature of the gas mixture, entering 2nd catalyst bed. In this
manner, temperature of gas mixture, entering other beds is controlled by quench-
ing, thereby, conversion in each bed is increased. Gas mixture from final catalyst
bed is taken out through a central pipe and taken to the heat exchanger for ex-
changing heat with incoming gas mixture. Overall effect is to gel definite conver-
sion per pass through the converter without exchanging heat in external heat
exchangers.
Process Engineering Channel

Since number of moles reduce during syntheses of ammonia and methanol,

high pressure is employed. Quench bed reactor for such syntheses are multi-layer
wall vessel. As explained earlier, wall temperature of the reactor is kept low by
the flow of ingoing gas mixture in the annulus. This is advantageous as at low
temperature, lower wall thickness is required.
In Fig. 10.11(a), gas flow through the catalyst bed is axial while in Fig. 10.11(b),
it is radial. Design, shown in Fig. 10.11(b), results in lower pressure drop in the
@ProcessEng

gas mixture, resulting in energy saving. Volume of catalyst in each bed differs.
Volume of 4th bed is highest while that of 1 st bed is lowest. Volumes are decided
by reaction rate, catalyst activity and safety margine against possible deactiva-
tion due to catalyst poisons.
While dissociating nitrous oxide to nitrogen and oxygen, increase in moles
takes place. According to Le Chatelier's principle, low pressure favours the reac-
 Process Design of Reactors

■*—'
C -C
'5 y. 2:
3
c
0 cx ?
"ui = O o &
C
c3 3 a <
CX y C3
X
w
-X
-
3
!A r /■
c3 \N.
0
■o

•>- -C
-3 / 3
\ o
O)
r1 cc
rG 3
-3 -3 X> CX o 0)
w 3: p- O CQ
CJ — -o
3 CQ 5 y o
CQ >. cc -3 C
tc >, fX\1 ^ (U
3 3
>-V o>
c u IS
O ■£ -Si
u
u ■Q.
u

SXj

I 3 3
cx = y 3 CQ M
o
r ra
3 y O o a <
3
3 <
3 3
3
O
Process Engineering Channel

1
:si J E

o
<
/
so 3 n ■y
3 3 > \
3 3
3 3 3
i~ 1 - CQ a
3 CQ P CQ
>>
@ProcessEng

>. >.
X 3 3
u
u u u
o
 Introduction to Process Engineering and Design

tion. Therefore, a quench bed reactor with multiple catalyst bed for dissociation
of nitrous oxide is designed for low pressure.
Design of fixed catalyst bed reactors for gaseous reactions thus can be innova-
tive. Process engineer can design an efficient system with best heat recovery
options. Some other designs of industrial fixed bed catalytic reactors are:
(i) packed bed reactor (ii) shell and tube heat exchangers in which catalysts
are placed inside the tubes (hi) annulus flow type reactors in which catalyst are
placed inside the inner tube. Feed gas first pass through the annulus and then
enter the inner tube. Product gases are taken out from the bottom of inner tube,
(iv) catalysts can be in form of mesh. Mesh of catalyst may be placed inside
tower. Feed gas mixture is introduced from the top of tower. Product gases leave
from the bottom of catalyst mesh. (Example: ammonia oxidation to nitric acid).
In some cases catalyst mesh may be wound around the tubes of shell and tube
heat exchanger. (Example: reactor of acetaldehyde plant. In partial oxidation of
elhanol vapour, silver catalyst in the form of mesh is wrapped around the tubes of
shell and tube heat exchanger.) Section 10.8.1 shows the industrially important
examples of fixed bed catalytic reactor.

10.8.1 Industrial Example of Fixed Bed Catalytic Reactor

Product Major reaction step Catalyst

1. Ammonia N2 + 3 H2 ^ 2 NHi Fe0/Fe203,
promoted by
AliOj and K20
2. Nitric acid 4 NH3 + 5 02 4 NO+ 5 H-,0 Pi and Rh
2 NO + O. ^ 2 N02
3 N02 + H20 -> 2 HNO, + NO
3. Sulphur trioxide S02 + 1/2 02 -> SO3 V205 + K20
(Sulphuric acid plant)
4. Methanol CO + 2 H2 —> CH3OH CuO
5. Formaldehyde CH3OH + 1/2 02 HCHO +
H20 Ag
6. Aniline C6H5OH + NH3 ^ C6H5NH2 +
Process Engineering Channel

C02 + H20 Ni Supported

on Al203
7. Disintegration of N20 ^ N2 + 1/2 02 Transition
nitrous oxide metal oxides
8. Ethyl benzene C6H6 + C2H4 ^ C6H5CH2CH3 Zeolite
(Refer Fig. 2.2)
@ProcessEng

Fixed bed catalytic reactors are operated in both adiabatic and nonadiabatic
manner. If the heat of reaction is small then adiabatic packed bed type reactor is
used as fixed bed reactor. In such type of reactor there is no provision for heat
transfer.
But the reactions with a large heat of reaction as well as reactions that are
extremely temperature sensitive are carried out in nonadiabatic reactors in which
 Process Design of Reactors

indirect heat exchange takes place by circulating heat transfer medium integrated
in the fixed bed. With large heat of reaction, shell and tube type design is pre-
ferred in which catalyst is inside the tubes and heat transfer medium is circulated
on shell side. Alternatively, multiple quench bed reactor can be used (e.g. ammo-
nia synthesis). When high pressure and high temperature reaction is carried out
with indirect heat exchangers, conversion per pass can be near equilibrium. How-
ever, in multiple quench bed reactor, temperature of final exit stream controls the
conversion per pass.
The heart of a fixed-bed reactor and the site of the chemical reaction is the
catalyst. The overall reaction taking place on catalyst surface can be theoretically
divided into the following five separate steps.
(i) Diffusion of the reactants from the gas space through the outer gas - parti-
cle boundary larger, macropores and micropores.
(ii) Chemisorption on active centers
(iii) Surface reactions
(iv) Desorption of the products
(v) Back-diffusion of the products into the gas space. Also deactivation of
catalyst due to fouling, poisoning and elevation in temperature must be
considered. In the development of rate equation only a few of these five
steps are considered which control the overall rate; other steps may be ei-
ther neglected or combined. These steps do not necessarily proceed in se-
ries or in parallel, frequently making it impossible to combine them by
simple means.
For different type of solid catalyzed reactions and for different mechanisms,
rale equations are given in Table 4.8 of Ref. 2.
s
For example, if the chemical reaction is A v R
Assumed mechanism for this reaction is
s
A +S v AS (Absorption)
s
AS s RS (Reaction)
s
RS s R+S (Desorption)
If desorption of R controls the overall rate, then rate equation is
Process Engineering Channel

/ N
Q
k CA- R
K
V
rR=— (10.22)
\ + kACA

where, rR = Rate of formation of product R (overall)

k = Overall reaction rate constant
@ProcessEng

kA = Reaction rate constant for forward reaction

K = Overall equilibrium constant for the chemical reaction
CA, CR = Concentrations of A and R, respectively.
All fixed bed catalytic reactors are assumed to behave like ideal plug flow
reactor. Equation used for the design or sizing of fixed bed reactor is
 Introduction to Process Engineering and Design

x
W 7 dXA
= J —r (10-23)
r
^Aa o A
where, W = Mass of catalyst, kg
Fao = Molar flow rate of limiting reactant in feed kmol/s
XA = Fractional conversion of limiting reactant A

Moles of A reacted
or =
Moles of A in feed

Moles of A reacted
-r. = Overall rate of reaction in
S ■ kg of catalyst

S = Surface area of catalyst, m /kg

Most difficult part is the development of reliable expression of overall rate of
reaction. It also requires detailed kinetic data.

10.8.2 Scale up Method

Any type of commercial scale reactor cannot be designed totally based on theo-
retical equations. It requires at least laboratory and/or pilot plant data of the reac-
tions involved. A satisfactory scale up procedure requires a stepwise empirical
approach in which the size of the reactor is increased successively. Basically the
rate of chemical reaction is independent of the size and structure of a reactor. But
the overall rate of reaction is influenced by rate of mass transfer and rate of heat
transfer. Rate of mass transfer and heal transfer are usually controlled by the size
and structure of the reactor. For example, due to significant wall effect smaller
size reactor provides higher value of mass transfer coefficient compared to larger
size reactor. Shell and tube type structure provides higher heat transfer coeffi-
cient, compared to jacketted tower type structure. Thus a chemical reaction is
indirectly affected by reactor type and scale. Based on only lab scale data it is not
possible to predict the reliable values of overall rate of reaction, reaction time
and product composition for commercial scale reactor.

Example 10.7
Process Engineering Channel

Design the fixed bed catalytic reactor for 1000 t/a diethylbenzene plant based on the
following data obtained on a pilot plant reactor.
Data of pilot plant reactor13
(i) Feed composition
Component Mass %
Ethyl benzene 89
Ethanol 11
@ProcessEng

Feed flow rate in pilot plant reactor = 100 kg/h, Feed temperature = 3750C
(ii) Chemical reaction
(a) Main reaction
1 atm
C6H5C2H5 + C2H5OH C6H4 - (C2H5)2 + H20
Ethyl benzene Ethanol Diethyl benzene Water
 Process Design of Reactors 721

Reaction temperature = 375° C

(b) Side reactions are taking place in the reactor.
(iii) Product composition:
Component Mass %
Diethyl benzene 16
Benzene 6
Ethyl benzene 74
Water 4
Product rate is approximately equal to the feed rate.
(iv) Catalyst: Zeolite with binders
Density of catalyst particle; 630 kg/m3
Catalyst porosity: 0.3
Form of catalyst: 1.5 mm extrudates of 4 to 6 mm length
(v) Type of reactor: Shell and tube heat exchanger type in which catalyst is placed
inside the tube.
(vi) Reaction is endothermic. It is carried out in isothermal manner. Dowlhcrm A is to
be circulated in liquid form on shell side to maintain the isothermal condition.

W kg of catalyst
(vn) = 17.3
FAo kg of ethanol in feed/hour

(viii) Superficial mass velocity of feed gas

G = 0.55 kg/(m2 • s)
Feed composition, feed temperature, reaction temperature, operating pressure, cata-
lyst, type of reactor etc. are same in pilot plant and commercial reactor.
Solution:
Capacity of plant = 1000 t/a of diethyl benzene (DEB)
Let number of working days per annum = 330 days

1000x1000
Production rate of DEB = = 126.26 kg/h
330 x 24

Let design production rate of DEB = 150 kg/h

Table 10.12 Product Composition for Commercial Scale Plant

Process Engineering Channel

Component Mass % kg/h

DEB 16 150.00
Benzene 6 56.25
Ethyl benzene 74 693.75
Water 4 37.50
100 937.50
@ProcessEng

Feed rate s Product rate

 722 Introduction to Process Engineering and Design

Table 10.13 Feed Composition for Commercial Scale Plant

Component Mass % kg/h

Ethyl benzene 89 834.375
Ethanol II 103.125
100 937.500

Ethanol is the limiting reactant. It does not appear in the product mixture which means
conversion based on ethanol is 100%
Mass of catalyst required in commercial scale plant = 17.3 x 103.125 = 1784 kg (min.)

Mass of catalyst
Volume of solid catalyst =
Density of catalyst

1784
= 2.8317 m3
630
Porosity of catalyst bed = 0.3
Bulk volume occupied by the catalyst = 2.8317/0.7 = 4.045 m3
Superficial mass velocity of feed gas
G = 0.55 kg/(m2 • s)
Total cross sectional area of catalyst or of tubes

(937.5/3600)
= = 0.4735 m2
0.55
Select 50 mm NB tubes of 14 BWG (3.76 mm) thickness
MOC of tube = SS 316
Tube OD = 50.8 mm
Tube ID = 43.28 mm
Total number of tubes required

0.4735
n, = — = 322
(7r/4) (0.043 28)
Length of tubes required

Net volume of catalyst 4.045

L=
Process Engineering Channel

n, x (7r/4) df 322 x (7r/4)(0.043 28)2

L = 8.539 m
Select the tubes of 10 m length. Above calculations have fixed the value of heat transfer
area available for heat transfer. Temperatures and flow rate of Dowtherm A should be
fixed to satisfy the heat transfer requirement.
Aav = N, Kdn L
@ProcessEng

= 322 X^-X 0.0508 x 10

= 513.89 m2
103 I
Heat duty, 6t = AHR x kmol/h of ethanol consumption = 29x1000 x —'"

= 65 013.6 kJ/h= 18.06 kW

 Process Design of Reactors 723

Calculations of fixed bed side film coefficient, hf.

dp = equivalent diameter of catalyst cylindrical particle, m

^ ^P ft ,1 C\2 c 1 n-9
= —(1.5) x5 x 10
6 4
dp = 0.002 565 m

dp 0.002 565
= 0.059 < 0.35
d. 0.043 28

=0.813 et~6d'ld')(dpG/nr (10.24)

G = 0.55 kg/(m2 • s)
k = 0.04 W/(m • K)
/u = 0.015 mPa • s = 0.015 x K)"3 Pa • s
,0.9
0.04 0.002 565x0.55
e(-6 x 0.059) x
h: = 0.813 x
0.043 28 0.015x10 -3

= 31.49 W/(m2 • 0C)

, \ 0.365
hi dp clpG
= 3.6 (10.25)

,0.365
h: x 0.002 565 0.002 565 x 0.55
= 3.6
0.04 ■,-3
\ 0.015 x 10 x 0.3 y
/i,. =457.51 W/(m2 • 0C)
Let hi = 31.49 W/(m2 • 0C) (Lesser of two values)
Shell side heat transfer coefficient, h0\
Let tube pitch, P, = 1.25 dn = 1.25 x 0.0508 = 0.0635 m
Type of tube arrangement = Equilateral triangular

Equivalent diameter, de = — (P,2 - 0.907 J2) (6.32)

dn
Process Engineering Channel

LI
(0.0635 - 0.907 x 0.05082) = 0.036 63 m
0.0508
Shell side mass flow rate, m\

B, = m C, At

Table 10.14 Properties of Dowtherm A at 380oor

C 14
@ProcessEng

Property Value

CL 2.5832 kJ/(kg ■ 0C)

H 0.135 mPa s
k 0.098 W/(m • 0C)
 724 Introduction to Process Engineering and Design

Let At = 20C for Dowtherm-A

18.06
m = = 3.4957 kg/s
(2.5832x2)
Density of Dowtherm A at 380oC, p, = 0.709 kg/L

w
Circulation . cl. = 3.4957 x, 3600 = 17.775 nrVh
rate, 3,.
0.709 1000
Shell side flow area, As:

{P,-d0)DsBs
A =
P.
Shell inside diameter. D •

'Nt- = 50 8 ( 322 12.285

D
h = do
V K,I / 0.319

(k, = 0.319 and «, = 2.285 from Table 6.2)

£),, = 1048.46 mm
Let Ds = 1065 mm
Baffle spacing, Bs = 0.4 Ds = 426 mm

(0.0635-0.0508)
As - x 1.048 46 x 0.426 =0.0893
0.0635

Co = — = 39.1456 kg/(m2 ■ s)

Reynolds number. Re:

deGs 0.036 63x39.1456

Re = = 10 621.5
P 0.135x10 -3

Prandtl number, Pr

C, p 2.5832 x 0.135 x 10""5 x 1O^

Pr = = = 3.558
0.098
Process Engineering Channel

0.14
p ^
K dc
= J, Re Pr.0.33
Pw

From Fig. 6.14, Jh = 0.0058 for 25% baffle cut

ht> x 0.036 63
— = 0.0058 x 10621.5 x 3.558a33
0.098
@ProcessEng

h0 = 250.55 W/(m2 • 0C)

Overall heat transfer coefficient, U0:
1 do ]n( d /d d l d l
1 . + _L + ' o ''> + o + o
U,- ho h nd 2 k., d
i hid d h
i i
 Process Design of Reactors

hod = hid = 5000 W/(m2 ■ 0C)

I | i 0.0508 In (50.8/43.28) 5o.8

U0 250.55 5000 2x16 43.28

1 50.8 1
x + x
5000 43.28 31.49
2 0
U0 = 23.8356 W/(m • C)
0, = U0-A A9jn = 18.06 x 103 = 23.8356 x 513.89 x ArInu
A%n = 1.4740C
Very low temperature difference is required for the required duty of heat transfer.
Hence, area available is adequate for heat transfer. Dowtherm—A will be circulated at
pressure above its saturation pressure (8.21 bar a) correspending to operating tempera-
ture of 380oC. This means shell will be under pressure.
Note: Empty volume of catalyst tubes works out to be 4.7272 m3 (based on 10 m tube
length) which is 17.11% in excess over the bulk volume of the catalyst (4.045 m3). In
reality, manufacturing tolerance of tubes (±12.5%) and support arrangement at the
bottom of the tubes will call for sufficient excess volume so that required volume of
the catalyst can be packed.
Catalysts are available in different forms; such as extrudates, Raschig rings, partition
rings, monolith structure, etc. Bulk volume of catalyst in each shape will be different.
Also pressure drop of the catalyst packed tubes is usually much higher than that of
clean tubes. Manufactures of catalysts provide data relating to pressure drop in the
catalyst bed and suggest right size of the tube (i.e. diameter).
Over a period of operation some catalyst may settle or crumble and pressure drop
may increase. All these aspects will have to be borne in mind while desiging a reactor
with the use of catalyst.

Exercises

10.1 Sulphuryl chloride (SO2CI2) formation is carried out in a batch reactor at 0oC and
330 kPa a. Reaction time is 6 h.
Reaction:
Process Engineering Channel

^^2(1) + Cl2(g) —> S02Cl2(|)

Sulphur dioxide chlorine Sulphuryl chloride
At the reaction conditions, sulphur dioxide is in liquid state and it is a limiting
reactant. % conversion of SO2 at the end of reaction (at equilibrium) is 60% when
10% excess of chlorine is used. Reaction is carried out in glass lined reactor. Heat
of reaction at 0oC is -394 U/mol (exothermic). For the production of 1000 kg of
SO2CI2 per batch,
@ProcessEng

(a) Decide the diameter and height of batch reactor.

(b) Select the suitable agitator for this gas-liquid reaction and calculate the rpm
and power required by the agitator.
(c) Calculate the heat duty of overhead condenser. Overhead condenser will recy-
cle almost all excess SO2 back to the reactor.
(d) Calculate the heat duty of jacket.
 Introduction to Process Engineering and Design

10.2 In Example 10.5, a jet reactor is used for hydrogenation of edible oil. Instead of the
jet reactor, a reactor with gas induction type stirrer6 and spiral jacket is to be de-
signed as shown in Fig. 10.12. About 200 kg catalyst (1 to 2 pm particle size) is
used with 101 soybean oil. Use spiral baffled jacket (Fig. 10.9(c)) for heat transfer.
Following equation5 can be used to calculate jacket side heat transfer coefficient.
For/te > 10,000

h:D,. / \0.I4
D,
0 0 33
= 0.027 Re * Pr 1 + 3.5 (10.26)
TV D
i

(two holes - min.)

Gas

OO O©

oo OO
OO oo
ooo //'///
DN

>- -*
-D,-

Direction
of roation
U-J
Process Engineering Channel

45
r-i
D

(/.:■
@ProcessEng

Fig. 10.12 Gos Induction Type Tube Strirrer for Hydrogenation

where, De = Equivalent diameter for cross section, m

De=4W
W = Width of jacket, m
Devp
Re =
U
 Process Design of Reactors

m'/p
U= -
PW
p = pitch of baffle spiral, m
m' = Effective mass flow rate through spiral, kg/s
m' = 0.6 rn
m = Actual mass flow rate through spiral jacket, kg/s.
D
jo + Dji
Dj = , mean diameter of jacket, m

Inside heat transfer coefficient can be safely calculated by following equation .

\0.I4
2/3 /3
= 0.36/te /V (10.25)
,Pw
where, D, = Inside diameter of shell of reactor, m
If heat transfer area provided hy spiral jacket is not sufficient for the given heat
duty, then use internal helical coil. Coil side heat transfer coefficient can be calcu-
lated by Eq. (10.24).
For coil, D(, = dci, where, dcj = Inside diameter of coil. Also velocity of fluid
rh/p
through coil, vc. =
-di
4 "
10.3 Acetic acid is manufactured via carbonylation of methanol. Reaction is carried out
at 180oC and 50 atm a in presence of liquid phase rhodium promoted methyl iodide
as catalyst. Reaction is carried out in bubble column reactor. Acetic acid, itself is
used as solvent.
Determine the followings:
(a) Working volume of reactor.
(b) Diameter of reactor.
(c) Height of liquid inside the reactor.
(d) Heat duty of overhead condenser in which exist gas-vapour mixture is cooled
down to 40oC.
(e) Design a spiral baffled jacket around bubble column reactor.
Data:
(i) Reaction;
Process Engineering Channel

CH30H(I) + CO(g) CH3COOH(l)

CHjOH,,, + CH3COOH(l) ->• CH3COOCH3,,, + H20(l)

(ii) Bubble column reactor can be approximated as ideal mixed flow reactor. Its
uniform composition is 80% acetic acid, 10% methanol, 5% methyl iodide,
2.5% methyl acetate, and 2.5% water (by mass).
(iii) 10% excess of carbon monoxide is used.
@ProcessEng

(iv) Cooling water is available in the plant at 320C.

(v) Overall rate of reaction does not depend on KLa, if > 2 cm/s.
(vi) Rate of chemical reaction

I dNA . .
-rA = =kCA,k= 89.26 x lO"5 s"1
A V, dt
CA = Concentration of methanol, kmol/m3
 728 Introduction to Process Engineering and Design

(vii) Production rate of acetic acid = 50 tpd

(ix) Heat of reaction at reaction temperature
k.HR = -137 kJ/mole
(x) Conversion per pass = 70%
10.4 Design the fixed bed catalystic reactor for 1000 t/a ethyl chloride plant based on the
following data obtained on a pilot plant reactor.15
Data of pilot plant reactor:
(i) Feed flow rate = 0.025 53 kmol/h.
(ii) Feed composition
Component mole %
Methane 86.55
Ethylene 7.40
Hydrogen chloride 6.05
(iii) Feed temperature = 171.10C
(iv) Reaction is taking place at 171.10C and 2859.22 kPa g.
C2H4 + HC1 -> C2H5C1
Ethylene Hydrogen Chloride Ethyl chloride
(v) Product composition
Component mole %
CH4 90.77
C2H4 2.88
HC1 1.47
C2H5C1 4.88
(vi) Catalyst: Zirconium oxychloride supported on silica gel
Bulk density = 650 kg/m3
Porosity of catalyst bed = 0.32

.... W kg catalyst
(vn) — = 177.62
F kmol of feed/hour
(viii) Superficial mass velocity of feed gas, G = 58.93 kg/(m2.h)
(ix) Rate of reaction

kg mol of ethylene converted

- / a = 2.62 x lO"4
(h • kg catalyst)
(x) Reaction is endothermic. It can be carried out in a shell and tube heat ex-
Process Engineering Channel

changer type reactor. Saturated steam can be used on shell side to maintain the
isothermal conditions. Feed composition, feed temperature, reaction tempera-
ture, operating pressure, catalyst, etc. are assumed same in pilot plant and com-
mercial scale reactors.

References
@ProcessEng

1. Leavenspiel, O., Chemical Reaction Engineering, 2nd Ed., John Wiley & Sons, Inc.,
USA. 1972.
2. Perry, R. H. and D. Green, Perry's Chemical Engineers' Handbook, 6,h Ed., McGraw-
Hill Book Co., 1984.
 Process Design of Reactors

3. Elvers, B., Hawking, S. and Schulz, G. (Editors), Ullmann's Encyclopedia of In-

dustrial Chemistry, Vol. B4, 5th Ed. VCH Verlagsgesellschaft, GmbH, Germany,
1992
4. Smith, J.M., Chemical Engineering Kinetics, 3rd Ed., McGraw-Hill Book Co., USA,
1981.
5. Bondy, F. and S. Lippa, Chem. Engg, 90 (7), 1983, p. 62.
6. Elvers, B., Hawking, S. and Schulz, G. (Ed.), Ullman's Encyclopedia of Industrial
Chemistry, Vol. B2, 5th Ed., Germany VCH Verlagsgesellschaft GmbH, Germany
1988, p. 25-15, p. 25-17 and 25-21 to 25-22.
7. Moore, S and S. Samdani, Chem. Engg., 101 (3), March, 1994, p. 32.
8. Doraiswamy, L. K. and Sharma, M. M., Heterogeneous Reactions; Analysis, Exam-
ples and Reactor Design, Vol.: 1 & 2, John Wiley & Sons, USA, 1983.
9. Rase, H. R, Chemical Reactor Design for Process Plants, Vol. 1 & 2, John Wiley &
Sons, Inc., USA, 1977.
10. Denbich, K.G. and Turner, T. C, Chemical Reactor Theory—An Introduction, 3rd
Ed., Cambridge University Press, 1984.
11. Van den Hark S. M. Harrod, Applied Catalysis A: General, 210, 2001, p . 207.
12. Fogler, H.S., Elements of Chemical Reaction Engineering, 3rd Ed., Prentice-Hall of
India Pvt. Ltd., New Delhi, 2003.
13. Bokade, V. V. and R. Joshi, Chemical Engineering World, 37 (6) June, 2002. p. 59.
14. Dowtherm A, Product Technical Data, The Dow Chemical, Co., USA 1991.
15. Thodos, G. and Stutzman, L., Ind. Engg. Chem., 50 (3), March, 1958, p. 413.
Process Engineering Channel
@ProcessEng
 Conversion Tables

Table Al. I Length Units

Metres Centimetres Inches Feet Yards

(m) (cm) (in) (ft) (yd)
m I 100 39.370 08 3.280 84 1.093 613
cm 0.01 1 0.393 701 3.280 84 x lO"2 1.093 613 x lO'2
inch 0.0254 2.54 1 8.333 333 x I0^2 2.777 78 x lO"2
ft 0.3048 30.48 12 1 0.333 333
yd 0.9144 91.44 36 3 1

Table Al. 2 Area Units

Square Square Square Square Square

Metres centimetres inches feet yards
(m2) (cm2) (in2) (ft2) (yd2)
m2 I 104 1550.003 10.763 91 1.195 99
4
cm- 10 1 0.155 1.076 391 x lO"3 1.195 99 x lO"4
inch2 6.4516 xlO"4 6.4516 1 6.944 444 x lO"3 7.716 049 x lO"4
ft2 0.092 903 929.0304 144 1 0.111 111
yd2 0.836 127 8361.273 1296 9 1
Process Engineering Channel

Table Al. 3 Density and Concentration Units

Kilograms per Grams per cubic Pound per cubic Pound per UK Pound per US
cubic meter centimetre foot gallon gallon
3
(kg/m ) (g/cm3) (lb/ft3) (lb/UK gal) (lb/US gal)
kg/m3 1 lO"3 6.242 795 x KT2 1.002 2 x 10'-2 8.345 402 x K)"3
g/cm3 1000 1 62.427 95 10.0224 8.345 402
@ProcessEng

lb/ft3 16.018 462 1.601 846 x lO"2 1 0.160 54 0.133 681

Ib/UKgal 99.776 5 9.978 x lO"2 6.228 842 1 0.832 675
Ib/USgal 119.8264 0.119 826 7.480 519 1.200 95 1
* 1 g/cm3 = 1 t/m3 = 1.000 028 g/mL = 1.000 028 kg/L
 Appendix I

1 7 r-i ■sC
o o b o
—<
c xx c X X
_c r-i
r~ o
00 (Nc (N 0-, X o-l CN
—H O-l
—H
Of) (A (M r~o o-, as w ^ X, m x
On O o C/3 N—' IN %
w
C/3 3" <^1 oo O 3 CN 0-1 —3
n O o o 0-1
D SD C, e2 —r —H X '—1
(3 3" " ' X
5
cs

c
o b2 7 7 7
15 o o— c—
CO ^ x ^ 3"
— a ON lO r- Vl X X _ X X
« 00 <o SO so ON x _ 31 X oo
CN) ON 3" oo (N H§e CN 31 3" 3" 31
X
- ^ On ON O <N r~i 3" oo X ON
— X <N oo OO 00 On 3-_ OO
E" On" 0-i (3 x — o c* ON O 3" —H b
O-l

7 t
o
—H O
X X X
r- r- —1 I, fl C3
£ 0- X 13 3" oo ri n
X 3" O X X X X
3" —i r- O (3 -s a 3" 3- <3
x; 3, oo X 13 o o 0-1
3 (3 IO —■ o C3 r-1 x
u ■O 31 IO — o O 0- o-i o4 3" o o
<3 o 3" O
0-1 0-1 o
c 0-1 0-1 0-1
r)
to
-T 7 (-1 o 1
o o o
—H o
«—H
O) X X X X
x
o 3" 3" 3" IO <u 3" —1 in
c
H- r- 0- On O-l 0~ 00
o 3, 03 —• g O- o-l
CN CN 3" < X X r~
X o o r-~ _aj t2 ro —i o
3 r-; IT) O ON
u X NO 00 C3 — O O -H 3" —i o
(N C^, |2
r- <3

ro,
to o (N o o
O o
■*H
O—• V
ss X X
X X, X o-
E X X, On 0-1 r~- 3"
o 00 O —— (3 00
§ E o- X X 3" 00 31 X —r
U 3 oo 3" X, O- — o-
13 C3 X) OO o •C X o o
o -c NO OO 3" 0^ o o 13 —r Cs
X o X,
Process Engineering Channel

3 O-l X X
o 3
U
V-J 7 7 r-i
b o o b r-.
—H —- b
—3
X X X X
3 X X, X 0-1 E X
o 00 ON — o-
0- X o 3" hllJ ^ X
O 00 — X X, o^ 0-1 X X
X o-, 13 3" OO O- 3" 00
3 X OO X, 0-; X O —
@ProcessEng

u 31 3" 13 o x NO
o X —3 o
o
—3 3" O On
—r

15 "3
to 00 00
X
o 00
3 S 3 7--
c o ^ 00 H
 Appendix I

Table Al. 6 Force Units

Newtons Kilograms force Dynes Pounds force Poundals

(N) (kgf) (dyn) (Ibf) (pdl)
N 1 0.101 972 105 0.224 809 7.223
kgf 9.806 65 1 9.806 65 xlO5 2.204 62 70.932
dyn I0~5 1.019 72 x 10^ 1 2.2 xlO"6 7.233 x lO"5
Ibf 4.448 22 0.453 592 4.448 22 xlO5 1 32.174
2
pdl 0.138 256 1.4098 x I0" 1.382 25 xlO4 3.1081 x 10^ 2 I

Table Al. 7.1 Pressure Units

Newtons per Standard Kilograms-force per Dynes per square

square metre Bars atmospheres square centimetre centimetre
N/nr (Pa) (bar) (atm) (kgf/cnr or at) (dyn/cm2)
N/nr (Pa) 1 lO5 9.869 223 x 10"6 1.019 716 x lO"5 10
bar 105 1 0.986 923 1.019 716 106
atm 101.325 x I03 1.013 25 1 1.033 227 101.325 x I04
kgf/car 908.665 x 102 0.980 665 0.967 841 1 9.806 65 x 105
dyn/cm2 0.1 lO"6 9.869 233 x lO""7 1.019 716x10^ 1
torr 133.3224 1.333 224 x lO"3 1.315 79 xlO"3 1.359 51 xlO"3 1333.224
in Hg 3386.388 3.386 395 x lO"2 3.342 105 x lO"2 3.453 155 x lO"2 33.863 886 x 103
mH20 9806.65 9.8067 x lO"2 9.6784 xlO"2 0.1 9.806 65 x 104
ft H20 2989.063 2.989 x lO"2 2.949 89 x lO"2 3.048 x lO"2 2.989 067 x 104
lbf/in2 6894.757 6.894 757 x lO"2 6.804 596 x K)"2 7.030 696 x lO" 2
6.894 757 x 104

Table Al. 7.2 Pressure Units (Contd.)

Torr or Barometric Barometric inches Pounds-force per

millimetres of mercury of mercury Head of water square inch
(torr or mmHg) (in Hg) m H20 ft H20 (lbf/in2)

N/nr
(Pa) 7.500 616 x KT3 2.952 999 x lO""4 1.019 72 x KT4 3.345 53 x lO"4 1.450 377 x lO"4
bar 750.061 6 29.529 99 10.1972 33.4554 14.503 77
atm 760 29.921 26 10.332 27 33.8985 14.695 95
kgf/cnr 735.5592 28.959 03 10 32.8084 14.223 34
dyn/cm2 7.500 617 x lO"4 2.952 999 x 10^ 5 1.019 72 x KT5 3.345 53 x lO"5 1.450 377 X lO"5
Process Engineering Channel

torr 1 3.937 008 x 10' 2 1.359 15 x KT2 4.460 351 x 10" 2 1.933 678 x lO"2
in Hg 25.4 1 0.345 316 1.132 92 0.491 154
m H20 73.5556 2.8959 1 3.280 84 1.422 334
ft h2o 22.4198 0.882 67 0.3048 1 0.433 526
lbf/in2 51.714 93 2.036 021 0.703 072 2.306 67 1
@ProcessEng
 Appendix I

Table Al. 8.1 Energy and Heat Units

Joules Kilowatt hours Kilocalories Kilogram-force

(J) (kWh) (kcaljT) metres (kgf • m)

J 1 2.777 778 x KT7 2.388 459 x KT* 0.101 972

kWh 3.6 x ID6 1 859.845 2 3.670 98 x I05
kcal1T 4186.8 1.163 x10 1 426.935
kgf • m 9.806 65 2.724 07 x 10"^ 2.3423 x lO"3 1
L ■ atm 101.325 2.814 583 x 10"5 2.420 107 x 10-2 10.332 31
BtU]T 1055.056 2.930 711 x lO"4 0.251996 107.586
Ibf • ft 1.355 818 3.766 161 x lO"7 3.238 315 x lO"4 0.138 255

Table Al. 8.2 Energy and Heat Units (Contd.)

Litre atmospheres British thermal units Pound-force feet

(L • atm) (Btulx) (Ibf • ft)

J 9.869 233 x lO"3 9.478 172 x 10 4 0.737 562

kWh 3.552 924 x 104 3.412 142 x 103 2.655 224 x 106
kcal,T 41.3205 3.968 321 3088.96
kgf • m 9.678 38 x lO"2 9.294 88 x lO"3 7.233
L • atm 1 9.603 759 x lO"2 74.733 51
BtU|T 10.412 59 1 778.1693
Ibf • ft 1.338 088 x lO"2 1.285 067 x lO"3 1

Table Al. 9 Specific Energy Units

Joules per kilogram Kilocalories per British thermal unit

(J/kg) kilogram per pound
(kcallx/kg) (Btulx/Ib)

J/kg 1 2.388 459 x lO"4 4.299 226 x lO"4

kclIT/kg 4186.8 1 1.8
Blu]T/lb 2326 0.555 556 1

Table Al. 10 Power Units

Process Engineering Channel

Kilogram Metric horse- Pound-

Kilowatts force metre powers force feet Horsepowers
(kW) per second (mhp) per second (hp)
(kgf • m/s) (Ibf • ft/s)
kW 1 101.971 44 1.359 62 737.562 2 1.341 022
3
kgf • m/s 9.806 6 xlO- I 1.3333 x 10-2 7.233 1.3151 x lO-2
@ProcessEng

mhp 0.7355 75 1 542.4764 0.986 32

Ibf • ft/s 1.355 82 x 10-3 0.138 25 1.8434 x 10"3 1 1.8182 x lO-3
hp 0.7457 75.0395 1.013 87 550 1
 734 Appendix I

Table Al. I I Temperature Units

Degrees Kelvin Degrees Celcius Degrees Fahrenheit Degrees Rankine

(K) TO (0F) (0R)
K T r+ 273.15 5/9 (U + 459.67) 5/9 r
0 5/9 (7'-459.67)
C T- 273.15 t 5/9 (/' - 32)
0
F 9/5 T - 459.67 9/5 r+32 t' T - 459.67
°R 9/5 T 9/5 r + 491.67 t' + 459.67 r

Table A 1.12 Absolute Viscosity Units

kg/(m ■ s) or Poise (P) or Ib/(ft • s)

N • s/m2 g/(cm • s) or dyn • s/cmr

kg/(m • s) 1 10 0.671 97
Poise 0.1 1 0.067 197
Ib/(fts) 1.488 162 14.881 62 1
1 Poise = 100 certipoises (cP) = 100 mPa • s

Table A 1.13 Kinematic Viscosity Units

m2/s Stoke (St) ft2/s

m2/s 1 I04 10.763 91

Stoke lO"4 1 1.076 391 x lO"3
ft2/s 0.092 903 929.03 1

1 St = 100 cSt

Table A 1.14 Thermal Conductivity Units

W/(m ■ K) kcalIT/(h ■ m ■ 0C) Btulx/(h ■ ft ■ 0F)

W/(m • K) 1 0.859 854 0.577 789
kcalij/fh ■ m • 0C) 1.163 1 0.671 969
BtuIT/(h ■ ft ■ °F) 1.730 735 1.488 164 1

Table A 1.15 Heat Transfer Coefficient Units

Process Engineering Channel

W/(m2 • 0C) kcalIX/(h • m2 ■ 0C) BtU|X/(h • ft2 • 0F)

W/(m2 ■ C) 1 0.859 854 0.176 11

kcalIT/(h ■ m2 • 0C) 1.163 1 0.204 816
BtuIX/(h • ft2 • 0F) 5.678 264 4.882 432 1
@ProcessEng

Reproduced with the permissions of

(i) Thermodynamics Research Centre (TRC), USA from its Publication: Reprint of the
Introduction to the TRC Thermodynamic Tables: Non-Hydrocarbons, December 31.
1991 and
(ii) International Union of Pure and Applied Chemistry (IUPAC), UK from its Publica-
tion: Quantities, Units and Symbols in Physical Chemistry, Edited by I. Mills, T. Cvitas,
K. Homann, N. Kallay and K. Kuchitsu, 2nd Ed., Blackwell Science Ltd., UK, 1993.
 Appendix
2

Viscometer

Conversion Chart

1000

700
500
400 "
300 4?

200

100
so
60
4- 50
40
30

20

10
Process Engineering Channel

Given : Sayboli Seconds Universal - 120

2 - Results ; Kinematic Viscosity = 23.9cS
Saybolt Seconds Furol =16.1
Degrees Engler = 3.4
Redwood No. I Seconds = 104.1
Engler Seconds = 174.5
@ProcessEng

20 30 40 60 100 200 300 600 1000 2000 5000

Time in Seconds : Engler, Redwood, Saybolt Universal & Euro I

3 456 8 10 20 30 40 60 100 200 300 500

Degrees-Engler
Kinematic Viscosity Units
 Index

Absorber 567-654 PHE over shell and tube heat exchanger

criteria of selection 568. 569 272
process design 569, 606, 612,615, 635 plug flow reactor 645
types of 567 supercritical extraction over liquid-liquid
Absorption 567-654 extraction 367
exothermic 569, 615 U-tube heat exchangers 154
of HCI gas in 569,615 vacuum distillation over atmospheric dis-
falling film type absorber 615-635 tillation 383
in a packed tower 568, 569-606 Agitator 344 to 346
of SO2 in spray chamber 568, 606-611 anchor type 661, 684
of SO2 in venturi scrubber 613-615 crossbeam and blade type 662, 684
physical 569 gas induction type 684, 726
with chemical reaction 568, 569 helical ribbon type 662, 687
Activity coefficient 201,327,385 high shear mixer type 662
its determination by paddle type 661,684
NRTL method 385,557 Pfaudler 661,684
UNIFAC method 385 pitch blade type 661, 687
UNIQUAC method 385 power correlations for 345
van Laar equation 523 propeller type 661,687
Activity of a component 327 turbine type 661, 684
Adiabatic compressor 106 AIChE method 454-456
Advantages and disadvantages of Air cooled heat exchanger 159, 160, 249
Process Engineering Channel

air cooler over water cooler 159 induced draft type 249
batch reactors over continuous Reactors forced draft type 249
663 Air heater 249
brazed aluminium plate fin heat ex- Analytical report 47
changer over other types 295 Anchor agitator (stirrer) 661. 684
bubble type reactor over stirred tank type Annular flow 167
reactor 700 ANSI standards for PFD and P&ID 61
@ProcessEng

fixed tube heat exchangers 154 "API 13

gas induction type agitator 685 Applications of
jet reactors over agitated vessel type re- liquid-liquid extraction 326
actors 685 supercritical extraction 369
mixed flow reactors 675 short path distillation unit (SPDU) 496
mixer settler 343 Atomic Mass 10
 Index

Avogadro's number 11 Bonnet of a shell & tube type heat exchanger

Antoine equation 13 155,156
Approach to wet bulb temperature 159 Brazed aluminium plate-fin exchanger 251
ASMECode 134 Brines 157, 158
Auxiliary heat transfer medium 547 Boyko-Kruzhilin equation 167
Azeotrope 15, 512 Brazed aluminium plate fin type heat ex-
its compositions 513-516 changer 294, 295
separation thereof 517 construction and working 295
heterogeneous 515 Bubble cap tray 441
homogeneous 513,514 Bubble column reactor 697-713
maximum boiling 514 advantages and disadvantages over agi-
minimum boiling 513 tated vessel type reactor 700
Azeotropic distillation 39, 517, 518 factors affecting its performance 698
Bubble point 200, 202
Back-mix reactor 646 calculations of 202
Back mixing 698
Bare tube area 251 Calibration of
Baffle 146-147 orifice meter 117-119
dam type 147 rotameter 120-127
Cap type packing support 492
disc and doughnut type 147
Capacity ratio curve 541
for condensers 147
Carbon dioxide (CO-,)
orifice type 147
critical properties of 364, 367
nest type 147
p-t diagram 364
segmental type 147
Catalytic distillation 502-512
Baffle cut 147
contacting devices for 506
Bale packing 506
bale packing for 506
Batch ditillation 475-493
structured packing for 507
with rectification 478-493
Centrifugal pump 101 -105
simple 475-478
characteristics of 104
Batch operations 44
viscosity correction chart for 101, 102
Batch reactors 658. 659. 663
Ceramic packing 583, 585
advantages and disadvantages over con-
Channel cover of shell & lube type heat ex-
tinuous reactors 663
changer 156
performance equation 663
Channeling in packed tower 587
Batch type supercritical extractor 369
Checking for
"Baume 13
Process Engineering Channel

liquid entrainment 446

Beam type packing support 588 weeping 448
Bell cap liquid redistributor 587 Characteristics of random packing 573-574
Bell's method 247 Chemical technology 39, 40
Bessel function 253 Coefficient of heat transfer
Binary distillation 389, 398 boiling 219
Binodal curve 330 condensation 165, 172
Blower 105, 106
@ProcessEng

with no phase change 164

centrifugal 105 Coefficient of performance 47, 547
Lobe type 105 Coils
Block diagram 42. 55, 56 common arrangements 714
Bogart equation 482 Colburn and Hougen method 192
Boiling point 13 Common arrangements for jackets and coils
normal (at atmospheric pressure) 13 714
 | 738 Index

Conversion tables 730-734 Crystallization 501

Cooler freeze 501
air type 159,160
of solids 311-314 Dam baffle 147,201
Cooling medium 157-160 Decaffeination of coffee 371, 372
air 157-160 Decantation 346
brine 157, 158 Decanter 346-348
cooling water 157-160 design calculations of 346-348
chilled water 157,158 horizontal type 346-348
oil (thermic fluid) 157, 158, 159 vertical type 346, 347
Cooling tower 159,160 Degree of completion of reaction 17, 682
Compressor 70, 106-108 Degree of freedom 381, 440
adiabatic 106 Density 3, 12
isothermal 106 Derived dimensions 2-5
poly tropic 106 Design of a hydrogenation reactor 687-697
Compressible fluid 70 Desired properties of solvent
Comparison of pervaporation, adsorption for absorption 571
and distillation 555 for extraction 327
Condensation coefficient 165,172 Determination of
shell side 172 activity coefficient 387, 522, 557
tube side 165 LLEdata 327
Condensation with noncondensables 183, VLE data 385
192 Determination of Hoc 578-581
Condensation with subcooling 183 Determination of transfer units
Continuous contact type extractor 343 for absorption 571
Continuous extractor 343 for extraction 334
Continuous flow reactor 644 Determination of theoretical stages
Continuous stirred tank reactor (CSTR) for absorption 641
646, 647 for distillation 398, 411, 419, 432
Continuous phase 345 for extraction 333, 334
Conversion 17.682 Determination of tower diameter
Conveyor cooler 314 for sieve tray tower 442-444
Coriolis flow meter 113,114 for packed tower
Cornell's method 580,581 for absorber/distillation 576-578
Corrosion 160 for extractor 353
Cosolvents and surfactants 370, 371 Dew point 200, 202
Process Engineering Channel

Countercurrent type packing support calculations of 202

mesh type 588 Differential continuous contact extractor
welded ring type 588 343, 353-363
Crawford-Wilke correlation 353, 354 Differential pressure type volumetric flow
Critical heat flux 220 meters 110
Critical pressure 14 Differential thermal expansion 153
Critical properties 14, 367 Diluents 325
@ProcessEng

pseudo 14,229 Dimensions 1-5

Critical surface tension of packing Material fundamental 2
580 derived 2-5
Critical temperature 14 DIN standards for PFD and P&ID 61
Critical temperature drop 218 Dispersed phase 345
Critical volume 14 Distillation 378-566
Cross beam and blade stirrer 662, 684 azeotropic 517
 Index

batch 475 Entrainer 517

binary 381,398,406 Entrainment 446, 456
catalytic 503 Equation of state 14
extractive 518 ideal gas law 14
multicomponent 381,410 Equation tearing procedure 439-441
pressure swing 520 Equilibrium constant 201, 203
reactive 501 Equilibrium curve 330, 390
short path 379,493 Equilibrium line 329
Distillation columns 378 Equipment data sheet 45
process design steps 380 Equivalent diameter 170
selection criteria for 378 for square pitch 170
Distributed components 381 for triangular pitch 170
Distribution coefficient 327 of fin 250
Dittus-Bolter equation 164 Equivalent length of pipe 75
Divided flow shell 148 for fittings and valves 75, 76
Divided wall column 543 Equivalent number of velocity head
Downcomer 451, 452 for fittings and valves 76
checking of residence time 452 ERW pipes 75
flooding in 443 ETBE manufacture 507-512
pressure drop in 452 catalytic distillation process 509
effect of various parameters on 511
various types 451
conventional process 507
circular 451
Exothermic absorption of gases 617-619
inclined 451
of HC1 617-619
segmental 451
of ammonia 617
selection criteria for
Expansion joint 152, 153
Dummy tubes 249, 71
Extract phase 325
Extractive distillation 518-520
Eddy diffusivity 456
design procedure 519, 520
Eduljee's equation 449
selection criteria for solvent 519
Efficiency of pumps 87
industrial applications 519
Efficiency of sieve tray 453-456
Extractor 342-363
Ejectors for distillation system 544-546
agitated column type 343
Electrical units 7
batch type 343
quantity of 7
centrifugal type 343
Electromagnetic flow meters 113 continuous 343
Energy 6, 19 design of 343-363
Process Engineering Channel

Energy balances 19 mixer settler 343-353

Energy conservation in distillation packed tower type 353-363
energy efficient distillation by design rotating disc type 343
539 Extractive reaction 501
efficient operation of column 554
by advanced process control 540 Fans 70
by heat integration 539 axial flow 70
@ProcessEng

by use of high efficiency packing/tray centrifugal 70

540 Fanning or Darcy equation 71
with the use of heat pump 543-548 Fanning friction factor 72, 73
Enriching section 390 Falling film absorber 615-635
Enthalpy 6 advantages an disadvantages of 615
internal 6 of HCI (its design) 617-635
total 6 of ammonia (its design) 617
 Index

Faraday's law of conductance 113 Fluidized bed reactor 660

Fensky's equation 398,410 Force 5
Film wise condensation 182 Newton 5
Fin efficiency 253-255 Forced circulation reboiler 217, 239, 247
Finned tube heat exchanger 250 Forced draft air cooled heat exchanger 249,
various types 250 250
Fixed bed catalytic reactor 713-725 Fouling coefficient
design of 715-720 for shell and tube heat exchangers 175
examples of 718 for plate heat exchangers 274
scale-up 720 Francis formula 447
Fixed tube sheet shell & tube heat Freeze crystallization 501
exchanger 135, 154 Friction factor
advantages and disadvantages of 154 shell side 171
Floating head shell & tube heat exchanger tube side 169
154, 155 Freezing point 20
advantages and disadvantages of 154 Froude number 345
pull through type 155 FUG method 410,411
split ring type 155 FUE method 410
Flooding Fugacity coefficient 201. 385
in packed tower type absorber 576 Fundamental quantities 1, 2
in packed tower type extractor 354
in tray tower 443 Gas absorption 567-654
downcomer flooding 443 Gas expansion and shrinkage 699
jet flooding 443 Gas film controlled absorption 575
Flooding velocity Gas injection type packing support
in falling film absorber 617 beam type 587
in packed tower 576, 577 cap type 588
in absorber/distillation column 443,576 Gas induced agitator 39, 57, 684, 726
in extractor 354 Gas phase transfer unit 455
in sieve tray tower 443 Gas phase mass transfer coefficient 579
Flow arrangement in PHE 271 Gasket material for PHE 271
Flow meters 110-127 Generalized flooding and pressure drop cor-
electromagnetic type 113 relation 577
Coriolis 113 Gilliland's correlation 411
flow nozzles 114 Gilmore's equation 192
orifice type 110,111,115-119 Grand composite curve 299. 300
Process Engineering Channel

rotameters 111,112,119-127 Green engineering 48. 49

ultrasonic 113 Green chemistry 48,49
venturi type 114.132 Gross calorific value 22
volumetric 113
vortex 110, 111 Heavy key component 381
weirs 113 Heat 6
Flow sheet of batch supercritical extraction Heat capacity 19,20
@ProcessEng

369 molar (isobaric/isochoric) 19,20

Fluid 70 Heat duty 155,218
compressible 70 Heat of absorption 30, 32
incompressible 70 Heat of combustion 22
Fluid allocation 160, 161 Heat of formation 22
Fluid bed cooler 311-313 Heat of mixing 27, 28
Fluid moving devices 70, 83 Heat exchanger design software 139
 Index

Heat exchangers based on continuous phase 354

brazed aluminium film type 294 determination by experiment 359
finned tube type 249 Height equivalent to theoretical plate
plate type 270 (HETP) 380,453
shell & tube type 134 for various packing 453
spiral type 281 Helical coil 714
Heat exchanger networking 295 Helical ribbon impeller 662, 687
Heat of reaction 22 High efficiency packing/trays 540
endothermic 22 High shear mixer 662
exothermic 22 Heterogeneous azeotrope 515
Heat integration in distillation column 539. Hold down plate 588
540 Homogeneous azeotrope 513,514
Heat pump for distillation 543-548 maximum boiling 514
Heat transfer area 164 minimum boiling 513
calculations thereof 164 Horizontal condenser 165.172,182
Heat transfer coefficient Horizontal spray chamber 607
for air cooler/heaters 253 Hot oil (thermic fluid) cycle 159
for agitated vessel 727
for bubble column reactor 704 Ideal batch reactor 658, 663
for condensation 165 advantages and disadvantages of 663
for condensation with noncondensables its performance equation 663
192 Ideal gas law 14
for falling film absorber 619 Ideal mixed flow reactor 674, 675
for no phase change 164 Ideal plug flow reactor 644-646
for nucleate boiling 219 Inclined downcomer 451
for plain jacket 709 Incompressible fluid 70
for plate heat exchanger 273 Induced draft air cooled heat exchanger 249,
for spiral baffle jacket 725 250
for spiral heat exchanger 285 Industrial applications of liquid-liquid ex-
overall 173 traction 326
typical values 163 Industrial examples
Heater of batch reactor 658
air type 249,250 of bubble column reactor 700
Heat transfer in solids 311 -321 of mixed flow reactor 675
Heating medium 157,158 of plug flow reactor 674
auxiliary medium 547 Industrial strippers 527
Process Engineering Channel

condensing fluids 157,158 Inline mixer 41,57,672

flue gas/hot air 157. 158 Internal coil in a vessel 714
molten salt 157,158
oil (thermic fluid) 157, 158 Jackets 713,714,725
saturated steam 157-159 common arrangements of 714
sodium/potassium alloys 157 limpet coil type 714
Hegstebeck-Geddes equation 386 plain 713,714
@ProcessEng

Height of equivalent overall transfer spiral baffle type 713,714,725

unit for absorber heat transfer coefficients for
based on gas phase 578 calculations thereof 709, 725
based on liquid phase 578 selection criteria of 713
Height of equivalent overall transfer unit for Jet flooding 443
extractor Jet reactor 57, 660, 685
based on raffinate phase 354 Joint efficiency 75
 Index

Joule 2, 6 for air coolers/heaters 256, 257

for plate heat exchangers 272, 273
Kay's rule 670
KATMAX structured packing 507 McAdams, Drew and Bay's equation 619
Kettle type reboiler 217-235,247 McCabe-Thiele method (diagram) 390, 398
process design steps 218-221 Malokanov equation 411
selection criteria of 247 Mass 2
Key components 380,381 atomic 10, II
light key 381 molar 2, 10
heavy key 381 Mass fraction 11
split key 381 Mass flow meter
Kt values for hydrocarbons 203 Coriolis type 113,114
Kirk Bride equation 416 Mass flow rate
Kremser equation 398 through orifice meter 115
through rotameter 120
Lacy's equation 642 through venturi meter 132
Latent enthalpy 20, 21 Mass transfer coefficients 579
of fusion 20 of gas phase 579
of sublimation 21
of liquid phase 579
of vaporization 20 Mass velocity 165,168
Le Chatelier's principle 501
Material balances 15-17
Lewis-Matheson method 419-423
without chemical reactions 16
Li method 669
involving chemical reactions 17
Light key component 381
MATHCAD® 394
Limiting reactant 17
Mean temperature difference (MTD)
Limpet coil 714
logarithmic 161
Linde trays 441
weighted 201
Liquid back-up in downcomer 452
Membrane reaction 501
Liquid crest over weir 447
Membrane distillation 501
Liquid distributors 585-587
MESH equations 440
different types 586, 587
Minimum amount of solvent
orifice type 586
for gas absorption 571
perforated pipe type 586
for liquid-liquid extraction 329
trough type 586
Minimum reflux ratio
weir type 586
for batch distillation 480
Liquid entrainment 221.446,456
Liquid flow patterns in sieve tray tower 445 for binary distillation 389-391
Process Engineering Channel

Liquid-liquid extraction 325-363 for multicomponent distillation 391,392

Liquid phase transfer unit 455 Minimum shell diameter for kettle type
Liquid phase mass transfer coefficient 579 reboiler 221
Liquid redistributors 587 Minimum wetting rate for different packing
bell cap 587 572
wiper type 587 Mist eliminator 581
Locations of pressure taps for orifice meter Mixed flow reactor 673, 674
@ProcessEng

116 Mixer settler 343-353

Logarithmic mean temperature difference Mixing of reaction systems
(LMTD) 161 gas-liquid mixture 684, 685
Loop reactor 660, 685 homogeneous liquid mixture 684
LMTD correction factors immiscible liquid mixture 686
for shell and tube heat exchangers 161, slurry 687
162 MKS system of units 1,2
 Index

Molar heat capacity 4,19,20 Open steam

isobaric 4, 19, 20 use in distillation 403
isochoric 4, 19, 20 Operating instructions manual (OlM) 45,
Molar mass 2,10 46
Mole 2, 11 Operating range of trays 441
Mole fraction 11 Optimum amount of solvent for gas absorp-
Molecular distillation 495 tion 572
Molecular sieve drying 581 Optimum design of distillation system 538
Monolithic reactor 661,686 Optimum pipe size 71
Morris and Jackson equation 572 Optimum pressure drop
Mostinski equation 219 in shell and tube heat exchanger 173
Multicomponent condensation 200, 201 Optimum reflux ratio 397
Multicomponent distillation 381, 410 Optimum solvent to feed ratio for extraction
Multiple catalytic reactors with external heat
331, 332
exchangers 715
Optimum tray spacing 446
Multiple quench bed reactor 716,717
Orifice coefficient
axial flow 716,717
for orifice meter 116
radial flow 716,717
for sieve tray 450
Multistage countercurrent extraction 329
Orifice meter 110, 111, 115 to 119
Murphree efficiency 247
advantages and disadvantages 115
process design steps 115, 116
Net positive suction head (NPSH) 61,
various tap locations 116
84-100
available 84, 85 Orifice type liquid distributor 586
for saturated liquid with dissolved gases Overall heat transfer coefficients
85-87, 90, 91 calculations thereof 173
required 84 for shell & tube heat exchangers 173
for calculations thereof 85 for plate heat exchangers 277
correction factors for high temperature for spiral heat exchangers 286
85 typical values 163
Non-distributed components 381
Normal boiling point 13 Packed tower 568, 569-606
Normal temperature and pressure (NTP) 14 Packing
NRTL equation for determination of activ- different types 581. 585
ity coefficient 557 random 585
Number of overall gas phase transfer units structured 581
575 selection criteria for 585
Process Engineering Channel

of packed tower 575 Packing factor 573, 574

of spray tower 607 Packing supports 587, 588
of venturi scrubber 612 beam type 588
Number of transfer units (NTU) cap type 588
for gas absorption 575, 576 gas injection type 588
for liquid-liquid extraction 335 countercurrent type 587, 588
Nucleate boiling 219 mesh type 588
Nusselt equation
@ProcessEng

welded ring type 588

for shell side coefficient 172 Paddle type agitator 661,684
for tube side coefficient 165 Pall rings 585
Nusselt number 164,170 Partial pressure 4, 15
Partition coefficient 326
Onda Takeuchi and Okumoto correlation
Partitioned distillation column 543
578-580
 | 744 Index

Pass partition plate Pressure swing adsorption 379, 555

shell side 145 Pressure swing distillation 517, 520, 521
tube side 149 Projected perimeter of fin 251
Peak pressure drop in bed 321 Propeller 345,661,687
Peclet number 455 Properties of solvents
Peng-Robinson equation 385 for absorption 571
Percent void space in packing 573. 574 for extraction 327
Perforated pipe type distributor 586 Properties of supercritical fluids 365, 367
Performance test run 45, 46 Pressure 2,6
Pervaporation 39,517,555 absolute 2
Peryluk column 543 critical 14
Pfaudler agitator 661, 684 gauge 2
Phases partial 4, 15
continuous 345 Pressure drop calculations for
dispersed 345 fluid bed cooler 321
extract 325 orifice meters 115
raffinate 325 packed tower 353, 354
Phase diagram plate heat exchanger 274
of carbon dioxide (CO2) 364 piping system (including in fittings and
of water (H20) 365 valves) 71-83
Phase equilibrium shell side 172
liquid-liquid 326, 327 sieve tray tower 448-451
vapour-liquid 384 spiral heat exchanger 287
Physical absorption 569 tube side 168
isothermal 569 two phase system 126
non-isothermal 569 venturi scrubber 612
Pilot studies 40 Process design
Pinch point 300 alternate designs 42
Pinch technology 296 Process flow diagram (PFD) 42, 54, 56-60
Pinch temperature difference 296 Process engineering 38
Piping & instrumentation diagram (P&ID) alternate routes 38, 39
43, 54, 60-67 Process intensification 50
Plait point 328 Process research 40
Plate heat exchanger 270-281 Projected perimeter of finned tube 251
Plug flow reactor 644-646 Pseudo critical properties 670
Point efficiency of sieve tray 454 Pump 70.83-105
Process Engineering Channel

Ponchon-Savarit Method 406 different types 83

Polar solvents 370
Porter and Jaffrey's method 192 Quench bed reactor
Positive displacement pump 83 axial 716,717
Positive displacement type flow meters 112 radial 716,717
Power 7 <7-line 390,391
Power correlations for agitators 345
@ProcessEng

Power number 345 Raffinate phase 325

Power requirement of Rankin coefficient of performance 547
agitators 345 Random packing 585
blower/adiabatic compressor 106 Raoult's law 15,385
fan 105, 106 Raschig rings 585
pump 87 Reaction completion 17,682,683
Prandtl number 164,170 degree of completion 682, 683
 Index

Reactive ditillation 501 -512, 517 Rigorous methods for multicomponent dis-
advantages and disadvantages of 501- tillation 410
505 equation tearing procedure 439
applications 507 Lewis-Matheson method 419
different ways of 505 relaxation methods 410
Reactors Thiele-Geddes method 432
different types 657-661 Robinson and Gilliland equation 398,401,
batch type 658, 659, 663 402
batch loop type 659 Roller wiper system 495
baffle tank type 660 Rotary cooler for solids 312
bubble column type 697-713 ROSE process 371-375
continuous stirred type 673. 674 Rotameter 111,112,119-127
fixed bed catalytic type 660, 713 calibration of 120-127
fluid bed catalytic 660 magnetic type 111, 112
gas induction type 658, 684, 726 standard 111, 112
heterogeneous continuous type 659, Rotating disc contactor 343
684-687 Rotating distributor plate 495
jet reactor 660, 685
monolith loop type 661,686 Saddles 585
plug flow type 644-646 bed type 585
tubular type 659 Intalox type 585
quench bed type 716, 717 Scale-up
Reactive and catalytic distillation 501-512 of agitated vessels 348, 349, 353
advantages and disadvantages 501-505 of fixed bed catalytic reactor 720
applications 507 Schedule number 74, 75
Reboiler Scrubber 567
bundle in column type 235 Sealing strip 152
forced circulation type 217, 239, 247 Seamless pipes 74
kettle type 217-235,247 Segmental baffle 147, 148
thermosyphon type 235-247 Selection criteria between horizontal con-
Recirculation ratio 236 denser and vertical condenser 182, 183
Recommended fluid velocities 71, 72 Selection criteria for different types of ab-
Rectification 479 sorbers 567
Recycle stream 18 Selection criteria for tray tower and packed
Redlich-Kwong equation 385 tower 379
Reflux 19,380 Selection criteria for solvents
Process Engineering Channel

Reflux ratio 19 for absorption 571

minimum 380, 389-392, 480 for extraction 327-329
optimum 39 for extractive distillation 519
Regular packing 581 Selection criteria for various types of gas-
grids 581 liquid reactors 701
stacked rings 581 Selection criteria for various types of trays
structured packing 581 441, 442
@ProcessEng

Relative volatility 378, 476 Selection of key component 381

Research & development 40, 43 Selection of operating pressure for distilla-
Residence time in downcomer 452 tion column 382
Residual pressure drop 451 Selectivity in reaction 17
Residuum 372 Selectivity of solvent 327
Reynolds number 164,170 Settler 346-348
 | 746 Index

Shear mixer 662 Steam ejector 544-546

Shell 137, 148 Steam stripping 527, 530
divided flow type 148 Stirred tank as absorber 569
single pass 148 Stoichiomtric factor 17
split flow 148 Stoichiometry 10
Shell side pass partition plate 145 Stoke's law 347
Shell & tube heat exchangers 134-175 Structured packing 507,581
as absorber 615-635 Subcooling 183
as reactors 672 Sudgen equation 356
different parts of 135-153 Supercritical extraction 364-377
different types 135.136,154,155 advantages and disadvantages 367, 368
Short path distillation 379, 493-500 applications 369, 370
applications 496-500 Supercritical fluids 364
design and working of 495, 496 critical properties of 367
economics 500 reactions in 686
SI prefixes 8 Superficial gas velocity 453, 698
SI system of units I -5 Superficial liquid velocity 578
base units 2 Supplementary units 2
derived units 2-5 Surface area of packing 573, 574
Sieder-Tate equation 164 Surface roughness 72, 73
Sieve tray of various materials 72
efficiency 453-456 Surface tension 458, 459, 580
Simple batch distillation 475-478 critical 580
Slurry reactions 687 Symbols
Smith-Brinkley method 410 of equipments 62
Smoker's equation 398 of piping, instruments and controls 64
Spacer 150 Synthesis of ETBE 507-512
Sparged vessel type reactor 713
Specific gravity 13 Tail gas scrubber 620
Spiral plate heat exchanger 281-294 TEMA 134, 156
advantages and disadvantages 281 designation 155. 156
design of 284-287 Tellerettes 585
flow arrangement 282, 283 Temperature 1,2, 14
standard dimensions of 285 absolute 1
Split backing ring 155 critical 14
Spray chamber/tower 568, 606-611 Thermal conductivity 5
Process Engineering Channel

horizontal 607 Thermal energy 3

vertical 606, 607 Thermal stress 152
Spray chamber design 606, 607 Thermally coupled
for SOj scrubbing 608-611 distillation 541,542
Spray cooling 313 direct sequence 541
Square pitch arrangement 145 indirect sequence 541
Stagewise extractor 342 side column rectifier 542
@ProcessEng

Standard heat of combustion 22 side stream stripper 541

Standard heat of formation 22 Thermocompressor for distillation system
Standard heat of reaction 22 545
Standard pipes 74 Thermosyphon reboiler 235-247
Stratified flow 254 horizontal 235
Static mixers 41,57. 672 vertical 235-247
Stationary cooler for solids 311 Thickness of pipe 75
 Index

Thiele-Geddes method 432-436 advantages and disadvantages 154

Tie line 329
Tierod 150 Vacuum distillation 383
Tinker's flow model 247-249 advantages and disadvantages 383
Total condenser 201 Valves & fittings
Tray spacing 446 equivalents lengths of pipe for 75, 76
Tray tower equivalent number of velocity heads for
different types 441 76
bubble cap 441 Valve tray 441
high capacity 441 Vapour recompressoion system for distilla-
sieve tray 441 tion system 546, 547
valve tray 441
Tray tower as absorber 568, 569, 635 Winkle method 454
Triangular pitch arrangement 145 Vapour pressure 13
Tridiagonal matrix method 439-441 Antoine equation 13
Triple point 20,21 Vaporizer 247
Troubleshooting 47,130 van Laar equation 522
Trough type distributor 586 Variable area flow meter 111
Tube 149 Vena contracta 115, 116
Tube bundle diameter 144 Vertical condenser 182,183
Tube hole count 137-144 Vertical spray tower 606, 607
Tube roller 151 Vertical thermosyphon reboiler 235-247
Tube to tubesheet joint 151 VLB data 384
expanded 151 Volume 6
welded 151 Von Karman effect 110
Tubeside pass partition plate 149, 150 Vortex meter 110, 111
Tubesheet (tube plate) 151 Venturi meter 114,132
Turbine type agitator Venturi scrubber 611-615
curved blade 345,661,684 for SOi scrubbing 613-615
flat blade 661,684 Viscosity
pitched blade 661, 687 conversion diagram 735
Turndown ratio 441 correction for centrifugal pump 101,102
0
Twaddell 13
Two phase flow 125-127 Water (H20)
estimation of pressure drop in steam-con- critical properties of 365
densate system 126 p-t diagram 365
Process Engineering Channel

Water cooled heat exchanger 159,160

Ultrasonic flow meter 113 Water hammer 125
Underwood's method 391, 392 Watson equation 21
UNIFAC method for determination of activ- Weeping 448
ity coefficient 385 Weep point 449
Units 1,2,5 Welded ring type packing support 588
conversion factors 730-734 Wetted surface of packing 580
@ProcessEng

different systems 1, 2 Wetting rate 572

UNIQUAC method for determination of ac- Weirs
tivity coefficient 385 for distillation tower 446
Universal gas constant (R) 3 for flow measurement 113
US customary units 1 Weir type distributor 588, 587
U-tube shell & tube heat exchanger 135, Weighted temperature difference 201
154 Wiped film evaporator 493
 Index

Wiper type redistributors 587 Yield 17

Wiremesh type packing support 588
Work 2,6 Zeolites 555
Zuber's equation 220
X values for air and perfect diatomic Gases
107
Process Engineering Channel
@ProcessEng