+

UNIVERSIDAD AUTÓNOMA DE NUEVO LEÓN

FACULTAD DE CIENCIAS QUÍMICAS
PROCESOS DE SEPARACIÓN Y LABORATORIO

Diseño de equipos de
destilación
Dra. Nancy Elizabeth Dávila Guzmán
+ Instructional Objectives 2

After completing this chapter, you should be able to:

 Explain the need in distillation for a condenser to produce

reflux and a reboiler to produce boilup.

 Determine the five construction lines of the McCabe–Thiele

method using material balances and vapor–liquid
equilibrium relations.

 Distinguish among five possible phase conditions of the

feed.

 Apply the McCabe–Thiele method for determining

minimum reflux ratio, minimum equilibrium stages, number
of stages for a specified reflux ratio greater than minimum,
and optimal feed-stage location, given the required split
between the two feed components.

Dra. Nancy Elizabeth Dávila Guzmán

+ 3

 Use a Murphree vapor-stage efficiency to determine the

number of actual stages (plates) from the number of
equilibrium stages.

 Extend the McCabe–Thiele method to multiple feeds,

sidestreams, and open steam (in place of a reboiler).

 Estimate overall stage efficiency for binary distillation from

correlations and laboratory column data.

 Determine the diameter of a trayed tower and the size of the

reflux drum.

 Determine packed height and diameter of a packed column.

Dra. Nancy Elizabeth Dávila Guzmán

+ Introduction 4

Distillation is defined as:

a process in which a liquid or

vapour mixture of two or more
substances is separated into its
component fractions of desired
purity, by the application and
removal of heat.

Dra. Nancy Elizabeth Dávila Guzmán

+ Introduction 5

Optimal reflux/minimum
reflux between 1.1 to 1.5.

Minimum theoretical
10.7 minimum stages/theoretical
theoretical stages. stages = 2 (common
practice).

Stage efficiency,
80%
Figure 1. Distillation of a
binary mixture of benzene
and toluene.

Dra. Nancy Elizabeth Dávila Guzmán

+ Introduction 6

Table 1. Representative commercial binary distillation operations.

Dra. Nancy Elizabeth Dávila Guzmán

 Some initial considerations 7

1. The column operating pressure in the reflux

drum should correspond to a distillate
temperature somewhat higher than the
supply temperature of the cooling water to
the overhead condenser.

2. If this pressure approaches the critical

pressure of the more volatile component,
then a lower pressure must be used and a
refrigerant is required as coolant.

Dra. Nancy Elizabeth Dávila Guzmán

+ Some initial considerations 8

Table 1. Representative commercial binary distillation operations.

Dra. Nancy Elizabeth Dávila Guzmán

 Some initial considerations 9

3. If the estimated pressure is less than

atmospheric, the operating pressure at the
top is often set just above atmospheric to
avoid vacuum operation, unless the
temperature at the bottom of the column is
limited by decomposition, polymerization,
excessive corrosion, or other chemical
reactions. In that case, vacuum operation is
necessary.

Dra. Nancy Elizabeth Dávila Guzmán

+ Some initial considerations 10

Table 1. Representative commercial binary distillation operations.

Dra. Nancy Elizabeth Dávila Guzmán

+ Some initial considerations 11

For given (1) feed, (2) desired degree of separation, and

(3) operating pressure, a minimum reflux ratio exists that
corresponds to an infinite number of theoretical stages;
and a minimum number of theoretical stages exists that
corresponds to an infinite reflux ratio. The design trade-
off is between the number of stages and the reflux ratio.

Dra. Nancy Elizabeth Dávila Guzmán

+ Extermal column balances 12

• Mass and energy balances around the entire column.

Circled variables are

typically specified in
design problems

Dra. Nancy Elizabeth Dávila Guzmán

Figure 2. Binary distillation column.
+ Extermal column balances 13

• Mass and energy balances around the entire column.

The overall mass balance is:

F=B+D

The more volatile component mass

balance is:

QR will be positive and

Fz=BxB+DxD QC negative.

The steady-stage energy balance

around the entire column is :

FhF+QR+QC=BhB+DhD

Dra. Nancy Elizabeth Dávila Guzmán

Figure 2. Binary distillation column.
+ Extermal column balances 14

• Mass and energy balances around the entire column.

The enthalpies can be

calculated from enthalpy-
composition diagrams or from
the heat capacities and latent
heats of vaporization:

Still two unknown variables:

hF=hF(z,TF, p);
hD=hD(xD,Treflux, p);
hB=hB(xB,saturated liquid, p) Qc, QR

Dra. Nancy Elizabeth Dávila Guzmán

Figure 2. Binary distillation column.
+ Extermal column balances 15

• Mass and energy balances around the entire column.

The total condenser changes the phase of the entering

vapor stream but does not affect the composition. The
splitter after the condenser changes only flow rates.

y1=xD=x0

The condenser mass balance is:

V1=L0+D
The external reflux ratio is:

R=L0/D How many unknown variables?

Dra. Nancy Elizabeth Dávila Guzmán

+ Extermal column balances 16

• Mass and energy balances around the entire column.

The condenser energy balance is:

V1H1+QC=DhD+L0h0

Since stream V1 is a vapor leaving

Since the reflux and distillate
an equilibrium stage in the
streams are at the same
distillation column, it is a
composition, temperature, and
saturated vapor. Thus:
pressure:
h0=hD
H1=H1(y1,saturated vapor, p)
V1H1+QC=hD(D+L0)=V1hD

With Qc known we can

QC=V1(hD-H1) solve the column energy
balance for QR.
Dra. Nancy Elizabeth Dávila Guzmán
+ Example 1. 17

A steady-state, countercurrent, staged distillation column

is to be used to separate ethanol from water. The feed is
a 30 wt % ethanol, 70 wt % water mixture at 40°C. Flow
rate of feed is 10,000 kg/h. The column operates at a
pressure of 1 kg/cm2. The reflux is returned as a
saturated liquid. A reflux ratio of L/D = 3.0 is being used.
We desire a bottoms composition of xB = 0.05 (weight
fraction ethanol) and a distillate composition of xD = 0.80
(weight fraction ethanol). The system has a total
condenser and a partial reboiler. Find D, B, Qc, and QR.

Dra. Nancy Elizabeth Dávila Guzmán

+ Enthalpy-composition diagram for ethanol-water at a pressure
of 1 kg/cm2.
18

Dra. Nancy Elizabeth Dávila Guzmán

+ Example 2. 19

A distillation column with two feeds is separating ethanol from

water. The first feed is 60 wt % ethanol, has a total flow rate of
1000 kg/h, and is a mix of liquid and vapor at 81°C. The second
feed is 10 wt % ethanol, has a total flow rate of 500 kg/h, and is
liquid at 20°C. We desire a bottoms product that is 0.01 wt %
ethanol and a distillate product that is 85 wt % ethanol. The
column operates at 1 kg/cm2 and is adiabatic. The column has a
partial reboiler, which acts as an equilibrium contact, and a total
condenser. The distillate and reflux are saturated liquids. Find B
and D in kg/h, and find Qc and QR in kcal/h.

a. External reflux ratio, Lo/D = 3.0

b. Boilup ratio, V/B = 2.5.

Dra. Nancy Elizabeth Dávila Guzmán

+ Example 3. 20

A distillation column receives a feed that is 40 mol% n-pentane

and 60 mol% n-hexane. Feed flow rate is 2500 lbmol/h, and feed
temperature is 30°C. The column is at 1 atm. A distillate that is 99.9
mol% n-pentane is desired. A total condenser is used. Reflux is a
saturated liquid. The external reflux ratio is L0/D = 3. Bottoms from
the partial reboiler is 99.8 mol% n-hexane. Find D, B, QR, Qc.

Dra. Nancy Elizabeth Dávila Guzmán

+ 21

Internal Stage-by-Stage Balances

 In the enriching section of the column it is convenient to use
a balance envelope that goes around the desired stage and
around the condenser.

The mass and energy balances are:

V j+1
= Lj+D

V yj+1 j+1
= L jx j + D x D

Qc+V H j+1 j+1

= L jh j + D h D

The equilibrium relationships are:

h = h (x )
j j j

H j+1
= H j+1 (y ) j+1 Note: j can be
from 1 to f-1,
x = x (y )
j j j where f is the
feed stage.
Dra. Nancy Elizabeth Dávila Guzmán
+ 22

Internal Stage-by-Stage Balances

 In the stripping section of the column it is convenient to use a
balance envelope that goes around the desired stage and
around the partial condenser.

The mass and energy balances are:

V =L k k-1
-B

V y =L x
k k k-1 k-1
-B x B

V H =L h
k k k-1 k-1
-B h +Q
B R

The equilibrium relationships are:

h k-1
= h k-1 ( x k-1)

H = H (y )k k k

x k-1
= x k-1 (y ) k-1

Dra. Nancy Elizabeth Dávila Guzmán

+ 23

Internal Stage-by-Stage Balances

 The phase and temperature of the feed affect the vapor and
liquid flow rates in the column.

The mass and energy balances are:

F +V + L = L +V

F h +V H
F f +1
+L h f -1
=L h +V H
f f

Dra. Nancy Elizabeth Dávila Guzmán

+ 24

Lewis Method
 In many cases the molar vapor and liquid flow rates in each
section were constant. This will occur if:

1. The column is adiabatic.

2. The specific heat changes are small compared to latent heat
changes. ¹
L L
3. The heat of vaporization per mole is constant (constant molal
overflow).
4. An alternative to conditions 2 ¹
V V
and 3 is: the saturated liquid and
vapor lines on an enthalpy-compositions diagram (in molar
units) are parallel.

For some systems, such as hydrocarbons, the latent heat of

vaporization per kilogram is approximately constant. Then the mass
flow rates are constant, and constant mass overflow should be used.

Dra. Nancy Elizabeth Dávila Guzmán

+ 25

Lewis Method
 Assuming constant molal overflow, the mass balance for the
enriching section is:

V y j+1 j+1
= L jx j + (V j+1
-Lj )x D

Solving for yj+1, we have:

æ ö
y j+1 = L j x j + çç1- L j ÷÷ x D
V j+1 è V j+1 ø
Since L and V are constant, this equation becomes:

æ ö
y =L x +
j ç
ç1- L ÷÷ x D Operation equation in
the enriching section.
V j+1
è V ø

Dra. Nancy Elizabeth Dávila Guzmán

+ 26

Lewis Method
 Assuming constant molal overflow.

For the stripping section:

æ ö Operation equation in
y =L x k-1 - çç L -1÷÷ x B the stripping section.
k
V èV ø

At the feed stage:

F h + (V -V ) H = ( L - L ) h
F
Hf+1 ≈ Hf and hf-1 ≈ hf

Dra. Nancy Elizabeth Dávila Guzmán

+ 27

Lewis Method
 Assuming constant molal overflow.

Combining mass and energy balances:

-L - hF q is the “quality”, the

qº L » H fraction of feed that is
F H -h liquid.

liquid flow rate below feed stage - liquid flow rate above feed stage
qº
feed rate

vapor enthalpy on feed plate - feed enthalpy

q»
vapor enthalpy on feed plate - liquid enthalpy on feed plate

Dra. Nancy Elizabeth Dávila Guzmán

+ 28

Lewis Method
 Assuming constant molal overflow.

From the mass balance:

L = L +q F

V = V - (1-q ) F

Dra. Nancy Elizabeth Dávila Guzmán

+ 29

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

Dra. Nancy Elizabeth Dávila Guzmán

+ 30

Dra. Nancy Elizabeth Dávila Guzmán

+ Introduction to the McCabe-Thiele method. 31

Equilibrium for top stage Stage 1 calculation on

on McCabe-Thiele
McCabe-Thiele diagram.
diagram.

Dra. Nancy Elizabeth Dávila Guzmán

+ Introduction to the McCabe-Thiele method. 32

Stepping off stages in Stepping off stages in

rectifying section. stripping section.

Dra. Nancy Elizabeth Dávila Guzmán

+ Introduction to the McCabe-Thiele method. 33

Dra. Nancy Elizabeth Dávila Guzmán

+ Introduction to the McCabe-Thiele method. 34

When stepping off stages from the top down, the

fractional number of stages can be calculated as:

dis tan ce from operating line to xB

Franction =
dis tan ce from operating line to equilibrium curve

The fraction is somewhat useful when the stage efficiency is < 1.

Dra. Nancy Elizabeth Dávila Guzmán

+ Introduction to the McCabe-Thiele method. 35

Feed line is obtained from the intersection of the

enriching and stripping operation equations:
æL-Lö FzF
y = -ç ÷ x +
è V -V ø V -V

An overall mass balance around the feed stage is:

F +V + L = V + L
Substituting in the feed line, dividing numerator and
denominator of each term b the feed rate F, and
using q, we get:
q 1
y= x+ zF
q -1 1- q
Dra. Nancy Elizabeth Dávila Guzmán
+ Introduction to the McCabe-Thiele method. 36

Type Feed T hF q Slope=q/(q-1)

Subcooled TF<TBP hF<h q>1 >1

liquid
Saturated TF=TBP h 1 ∞
liquid
Two-phase TBP<TF<TDP h<hF<H 0<q<1 (-)
mixture
Saturated TF=TDP H 0 0
vapor
Superheated TF>TDP hF>H q<0 0<slope<1
vapor

Dra. Nancy Elizabeth Dávila Guzmán

+ Introduction to the McCabe-Thiele method. 37

Dra. Nancy Elizabeth Dávila Guzmán

+ Introduction to the McCabe-Thiele method. 38

Dra. Nancy Elizabeth Dávila Guzmán

+ Introduction to the McCabe-Thiele method. 39

Optimum feed plate calculation

Lbelow× feed - Labove× feed

q=
feed flow rate

Vabove× feed -Vbelow× feed

f=
feed flow rate

Dra. Nancy Elizabeth Dávila Guzmán

+ Introduction to the McCabe-Thiele method. 40

Feed line calculations.

Calculate the feed line slope for the following cases:

a. A two-phase feed where 80% of the feed is vaporized

under column conditions.
b. A superheated vapor feed where 1 mole of liquid will
vaporize on the feed stage for each 9 moles of feed
input.
c. A liquid feed subcooled by 35ºF. Average liquid heat
capacity is 30 Btu/lmolºF and λ= 15,000 Btu/lbmol.
d. A mixture of ethanol and water that is 40 mol% ethanol.
Feed is at 40ºC. Pressure is 1.0 kg/cm2.
Dra. Nancy Elizabeth Dávila Guzmán
+ Complete McCabe-Thiele Method. 41

A distillation column with a total condenser and a partial

reboiler is separating an ethanol-water mixture. The feed
is 20 mol% ethanol, feed rate is 1000 kmol/h, and feed
temperature is 80°F. A distillate composition of 80 mol%
ethanol and a bottoms composition of 2 mol% ethanol are
desired. The external reflux ratio is 5/3. The reflux is
returned as a saturated liquid and CMO can be assumed.
Find the optimum feed plate location and the total number
of equilibrium stages required. Pressure is 1 atm.

Dra. Nancy Elizabeth Dávila Guzmán

+ Limiting Operations Conditions. 42

Total Reflux: Minimum equilibrium stages

Dra. Nancy Elizabeth Dávila Guzmán

+ Limiting Operations Conditions. 43

Minimum Reflux Ratio

Dra. Nancy Elizabeth Dávila Guzmán

+ Distillation Problems 44

Tarea para el 28 de agosto

A column at 101 kPa is to separate 30 kg/h of a bubble-
point solution of benzene and toluene containing 0.6 mass-
fraction toluene into an overhead product of 0.97 mass-
fraction benzene and a bottoms product of 0.98 mass-
fraction toluene at a reflux ratio of 3.5. The feed is sent to
the optimal tray, and the reflux is at saturation temperature.
Determine the: (a) top and bottom products and (b) number
of stages using the following vapor–liquid equilibrium data.

Dra. Nancy Elizabeth Dávila Guzmán

+ Distillation Problems 45

A distillation unit consists of a partial reboiler, a column with

seven equilibrium plates, and a total condenser. The feed is
a 50 mol% mixture of benzene in toluene. It is desired to
produce a distillate containing 96 mol% benzene, when
operating at 101 kPa.
(a) With saturated-liquid feed fed to the fifth plate from the
top, calculate: (1) the minimum equilibrium stages, (2)
minimum reflux ratio (L/D)min; (3) the bottoms composition,
using a reflux ratio (L/D) of twice the minimum; and (4)
moles of product per 100 moles of feed.
(b) Repeat part (a) for a saturated vapor fed to the fifth plate
from the top.

Dra. Nancy Elizabeth Dávila Guzmán

+ Distillation Problems 46

We wish to separate ethanol from water in a distillation column

with a total condenser and a partial reboiler. We have 200
kmol/h of feed 1, which is 30 mol% ethanol and is saturated
vapor. We also have 300 kmol/h of feed 2, which is 40 mol%
ethanol. Feed 2 is a subcooled liquid. One mole of vapor must
condense inside the column to heat up 4 moles of feed 2 to its
boiling point. We desire a bottoms product that is 2 mol%
ethanol and a distillate product that is 72 mol% ethanol.
External reflux ratio is L0/D = 1.0. The reflux is a saturated
liquid. Column pressure is 101.3 kPa, and the column is well
insulated. The feeds are to be input at their optimum feed
locations. Find the optimum feed locations (reported as stages
above the reboiler) and the total number of equilibrium stages
required.
Dra. Nancy Elizabeth Dávila Guzmán
 47

xD=0.72

One mole of
F2=300 kmol/h L/D = 1 vapor must
z=0.40 condense inside
subcooled liquid the column to
heat up 4 moles of
F1=200 kmol/h feed 2 to its
z=0.30 boiling point.
saturated vapor

xB=0.02

Dra. Nancy Elizabeth Dávila Guzmán

 48
Ethanol-water ELV, 101.3 kPa

Dra. Nancy Elizabeth Dávila Guzmán

 49

Feed 1: Saturated vapor, q1=0

Feed 2: Subcooled liquid

q2 = (Lbelow – Labove)/F2 q2=5/4

L V

F2

C
Lbelow =L’=L+F2+C L’ V’

C=(1/4) F2

Dra. Nancy Elizabeth Dávila Guzmán

 50

Top Operating Line (TOL):

æ ö
y= R x + çç 1 ÷÷ x D
R+1 è R+1 ø

y = 0.5 x + 0.36

Bottom Operating Line (BOL):

Dra. Nancy Elizabeth Dávila Guzmán

 51

xD=0.72

F2=300 kmol/h L/D = 1

z=0.40
subcooled liquid

F1=200 kmol/h
z=0.30
saturated vapor

xB=0.02

Dra. Nancy Elizabeth Dávila Guzmán

 MÉTODO DE PONCHON
+ SAVARIT
Desarrollo de método de Ponchon - Savarit
Zona de enriquecimiento (condensador total)

QC Balance global de materia

Vn+1 = Ln + D (1)
V1,
y1 Balance del componente más liviano
Lo, x0
D, yD yn+1 Vn+1 = xn Ln + yD D (2)
1
L1 , x 1 Balance de entalpía global
V2, y2
2
L2 , x 2 Vn+1 HVn+1 = Ln HL n + D HD + QC (3)
Vn, yn n (Considerando pérdidas despreciables)
Ln , x n
Sea Q’ = (D HD + QC) / D (4)
Vn+1, yn+1
A partir de las ecuaciones (3) y (4):
Vn+1 HVn+1 - Ln HL n = D Q’ (5)

(D Q’ cte)

Sustituyendo el valor de D de la ecuación (1) en (2) y (5), y

despejando Ln / Vn+1 (relación de reflujo interno) se tiene:

Ln / Vn+1 = (yD - yn+1) / (yD - xn) = (Q’ - HVn+1) / (Q’ - HLn) (6)

La ecuación (6) representa una línea recta en el diagrama entalpía-

composición, Hxy. La línea recta pasará por los puntos (xn, HLn), (yn+1,

Hvn+1) y (yD, Q’). El punto (yD, Q’) se denomina punto de diferencia

y se simboliza con DD (o P’). En el diagrama x,y la ec. (6) permite

graficar la curva de operación para la zona de enriquecimiento

Representación gráfica de la zona de enriquecimiento

DD Q’
Hv vs.y Evaluando la ec. (6) y la ec.(1) en n = 0:

L0 / V1 = (yD - y1) / (yD - x0)

H 3 = (Q’ - Hv1) / (Q’ – HLo) (7)
2 1
V1 =Lo + D (8)
HL vs. x
Sustituyendo (8) en (7):
x, y
Lo / D = (Q’ - Hv1) / (Hv1 - HLo) (9)

entonces,
Pendient
y e Ln / Vn+1
R = (Q’ - HV1) / (HV1 - HLo) (10)

x yD = x0
Zona de agotamiento (rehervidor parcial)

LN-3 , xN-3 Balance global de materia

VN-2, yN-2 N-2
LN-2, xN-2 LN-3 = VN-2 + B (11)

VN-1, yN-1 Balance del componente más

N-1
liviano
LN-1, xN-1
VN, yN N xN-3 LN-3 = yN-2 VN-2 + xB B (12)

Balance de entalpía global

LN , x N
LN-3 HLN-3 + QR = VN-2 HVn-2 + B HB
Vn+1, yn+1 (13)

B, xB (Considerando pérdidas despreciables)

QR Sea Q’’ = (B HB - QR) / B (14)
A partir de las ecuaciones (13) y (14) se obtiene:

LN-3 HLN-3 - VN-2 HVn-2 = B Q’’ (15)

(B Q’’ cte)

Sustituyendo el valor de B de la ecuación (11) en (12) y (15), y

despejando LN-3 / VN-2 (relación de reflujo interno) se tiene:

LN-3 / VN-2 = (yN-2 - xB) / (xN-3 - xB) = (HVN-2 – Q’’) / (HLN-3 – Q’’) (16)

La ecuación (16) representa una línea recta en el diagrama entalpía-

composición, Hxy. La línea recta pasará por los puntos (xN-3, HLN-3),

(yN-2, HvN-2) y (xB, Q’’). El punto (xB, Q’’) se denomina punto de

diferencia y se simboliza con DB (o P’’) La ec. (16) permite graficar la

curva de operación de la zona de agotamiento.

Aplicación del método P-S a la columna de destilación completa
(condensador total y rehervidor parcial)

Balance global de materia

F=D+B (1)

Balance global por componente

zF F = yD D + xB B (2)

Balance global de entalpía

F HF = D Q’ + BQ’’ (3)

Despejando F de (1) y sustituyéndola en (2) y (3):

D / B= (zF - xB) / (yD - zF) = (HF – Q’’) / (Q’ - HF) (4)

 Número mínimo de etapas (Nm) y relación de reflujo mínimo (Rm)

DD
Hv vs. y Hv vs. y
DDm
B

HL vs. x F HL vs. x D
DB

xB yD xB zF yD = x0

Número mínimo de etapas a reflujo total Relación de reflujo mínimo

 D1 Diagrama de Ponchon y Savarit

F, DD, DB están en línea recta

L0
V1
B F
D

D
H/h

D2
y

xB z xD
y, x
 DD
Diagrama de Ponchon y Savarit
Cálculo etapa a etapa
B F V1

D
H/h

DB

xB z xD
y, x
+ 62

Método de Ponchon-Savarit
1000 kg/h of a mixture containing 42 mole
percent heptane and 58 mole percent ethyl
benzene is to be fractionated to a distillate
containing 97 mole percent heptane and a
residue containing 99 mole percent ethyl
benzene using a total condenser and feed at its
saturated liquid condition. The enthalpy-
concentration data for the heptane-ethyl benzene
at 1 atm pressure are as follows:

Dra. Nancy Elizabeth Dávila Guzmán

+ 63

Método de Ponchon-Savarit

Calculate the following:

1. Minimum reflux ratio

2. Minimum number of stages at total reflux
3. Number of stages at reflux ratio of 2.5
4. Condenser duty
5. Reboiler duty

Dra. Nancy Elizabeth Dávila Guzmán

 Parameters for the design of
+ multiphase mass transfer units

Dra. Nancy Elizabeth Dávila Guzmán 64

+ 65

Stage and packed column

Trays Random packing Random mesh

Dra. Nancy Elizabeth Dávila Guzmán

+ 66

Type of stage columns

Bubble-cap trays

Sieve tray Valve tray

Dra. Nancy Elizabeth Dávila Guzmán

+ 67

Sieve-tray column

Dra. Nancy Elizabeth Dávila Guzmán

+ 68

Bubble-cap tray

Dra. Nancy Elizabeth Dávila Guzmán

+ 69

Trays, Downcomers, and Weirs

In addition to choosing the type of tray, the designer
must select the flow pattern on the trays and design
the weirs and downcomers.

Which flow pattern is appropriate

for a given problem? As the gas
High liquid rates
and liquid rates increase, the
tower diameter increases.

Cross-flow Double-pass

Dra. Nancy Elizabeth Dávila Guzmán

 + 70

Trays, Downcomers, and Weirs

A. Pilot plants B. Most common C. Difficult Disengagement D. Very low liquid flow

Dra. Nancy Elizabeth Dávila Guzmán

+ Limits of stable operation in a trayed tower 71

Weep point: Liquid begins

falling through the
perforations in the trays.

Dump point: weeping

point of 100%. Entrainment: Liquid passes
to the above tray. High gas
flow rates, froth formation.

Dra. Nancy Elizabeth Dávila Guzmán

+ 72

Entrainment

Dra. Nancy Elizabeth Dávila Guzmán

+ 73

Weeping

Dra. Nancy Elizabeth Dávila Guzmán

+ Tray details in a trayed tower 74

Weir: vertedero

Downcomer: tubo
de descenso

Dra. Nancy Elizabeth Dávila Guzmán

+ 75

Tray efficiencies

N equil
EO =
N actual
The number of equilibrium stages required for the given separation
should not include a partial reboiler or a partial condenser.

Dra. Nancy Elizabeth Dávila Guzmán

+ 76

Murphy efficiency

yout - yin
EMV =
y *out -y *in
xout - xin
EML =
x *out -x *in

Dra. Nancy Elizabeth Dávila Guzmán

+ 77

Tray efficiency

 To have data for the chemical system in the same type

of column of the same size at the same vapor velocity.
The Fractionation Research Institute (FRI) has reams of
efficiency data.
 To have efficiency data for the same chemical system
but with a different type of tray.
 If data are not available, a detailed calculation of the
efficiency can be made on the basis of fundamental
mass and heat transfer calculations.
 The simplest approach is to use a correlation to
determine the efficiency

Dra. Nancy Elizabeth Dávila Guzmán

+ 78

O’Connell correlation
EO = 0.52782 - 0.27511log10 (am) + 0.044923[log10 (am )]2

Dra. Nancy Elizabeth Dávila Guzmán

+ 79

Oldershaw column

Oldershaw column: 55,250,

columna de 10 platos con
2.8 mm de D.I.

Overall efficiency of 1-inch-diameter Oldershaw column compared

to point efficiency of 4-foot-diameter FRI column. System is
cyclohexane/n-heptane.

Dra. Nancy Elizabeth Dávila Guzmán

+ 80

Overall efficiency estimation

A sieve-plate distillation column is separating a feed
that is 50 mole % n-hexane and 50 mole % nheptane.
Feed is a saturated liquid. Plate spacing is 24 in.
Average column pressure is 1 atm. Distillate
composition is xD = 0.999 (mole fraction n-hexane) and
xB = 0.001. Feed rate is 1000 lbmol/h. Internal reflux
ratio L/V = 0.8. The column has a total reboiler and a
total condenser. Estimate the overall efficiency.
x 0 0.341 0.398 0.50 1.0

y 0 0.545 0.609 0.70 1.0

T(ºC) 101.1 87.22 85 82.22 70.55

Dra. Nancy Elizabeth Dávila Guzmán

+ 81

Column Diameter Calculations

 Fair’s procedure:
 Widely known
 Aspen Plus Simulator

This procedure first Uses a rule of Calculates the

estimates the vapor thumb to column
velocity that will cause determine the diameter.
flooding due to excessive operating
entrainment. velocity.

Dra. Nancy Elizabeth Dávila Guzmán

+ 82

Column diameter calculations

 The flooding velocity based on net area for vapor flow is

determined from:

æs ö r L - rv
0.2

u flood = Csb, f ç ÷ , ft / s
è 20 ø rv
 Where s is the surface tension in dynes/cm and Csb,f is the
capacity factor which is function of the flow parameter.

WL rv QL rL
FP = Flv = =
WV r L QV rV

Dra. Nancy Elizabeth Dávila Guzmán

+ 83

Column diameter calculations

Dra. Nancy Elizabeth Dávila Guzmán

+ 84

Column diameter calculations

6’’ tray spacing

log10 Csb, f = -1.1977 - 0.53143log10 Flv - 0.18760 ( log10 Flv )

2

9’’ tray spacing

log10 Csb, f = -1.1622 - 0.56014log10 Flv - 0.18168 ( log10 Flv )

2

12’’ tray spacing

log10 Csb, f = -1.0674 - 0.55780 log10 Flv - 0.17919 ( log10 Flv )

2

Dra. Nancy Elizabeth Dávila Guzmán

+ 85

Column diameter calculations

18’’ tray spacing

log10 Csb, f = -1.0262 - 0.63513log10 Flv - 0.20097 ( log10 Flv )

2

Tray spacing is usually selected

according
24’’ tray spacing
to maintenance
log C requirements.
= -0.94506 - 0.70234log F - 0.22618 log F ( )
2
10 sb, f 10 lv 10 lv

With
36’’ tray spacing the typical 24-inch tray
spacing, Csb,f ≈ 0.33 ft/s
log10 Csb, f = -0.85984 - 0.73980log10 Flv - 0.23735 ( log10 Flv )
2

Dra. Nancy Elizabeth Dávila Guzmán

+ 86

Column diameter calculations

 The operating vapor velocity uop is determined as:

uop = ( fraction)u flood , ft / s

Suggesting fraction value of 0.75.

Dra. Nancy Elizabeth Dávila Guzmán

+ 87

Column diameter calculations

 Also, it can be related to the molar vapor flow rate:

V MW v
uop = , ft / s
rV Anet (3600)
 The net area for vapor flow is

p (Di)2
Anet = h, ft 2
4
Typically n lies between 0.85 and 0.95.
where h Exact
is the fraction of the column cross-sectional
values are determine from the tray layout.
area that is available for vapor flow above the tray.
Then 1-h is the fraction of the column area taken up
by one downcomer.
Dra. Nancy Elizabeth Dávila Guzmán
+ 88

Column diameter calculations

 The diameter of the column:

4V MW v
Di = , ft
phrV ( fraction)u flood (3600)
 If the ideal gas law holds

4VRT
Di = , ft
ph(3600)P( fraction)u flood

The largest diameter should be used and rounded

off to the next highest ½-foot increment.
Dra. Nancy Elizabeth Dávila Guzmán
+ 89

Diameter calculation for tray

column
 Determine the required diameter at the top of the
column for the distillation column in Example
“Overall Efficiency Estimation”.

 Repeat the diameter calculation, except calculate

the diameter at the bottom of the column. For n-
heptane: MV=100.2, bp 98.4ºC, sp gravity=0.684, m
(98.4ºC)=0.205 cP., s(98.4ºC)=12.5 dynes/cm.

Dra. Nancy Elizabeth Dávila Guzmán

+ 90

 You have designed a sieve tray column with 0.3048

m tray spacing to operate at a pressure of 1.0 atm.
The value of the flow parameter is Flv = 0.090 and
the flooding velocity was calculated as 1.83 m/s.
Unfortunately, your boss dislikes your design. She
thinks that 0.3048 m tray spacing is not enough and
that your reflux ratio is too low. You must redesign
for a 0.6096 m tray spacing and increase L/V by
11%. Estimate the new flooding velocity.

Dra. Nancy Elizabeth Dávila Guzmán

+ 91

Sieve Tray Layout and Tray

Hydraulics
The vapor does not go straight
 The punched holes
upinfrom
the tray
theusually
holesrange in diameter from
1/8 to 1.0 inch.
The active hole area is
 Inconsidered
the range fromto½be
to 12-inch, efficiency is constant and at its
to 3-inches
highest level.
from the peripheral
3.8doholesa reasonable average

The use of standard punching patterns will be cheaper than

use of a nonstandard pattern.
Dra. Nancy Elizabeth Dávila Guzmán
+ 92

Sieve Tray Layout and Tray

Hydraulics
 Typically, 4% to 15% of the entire tower area is
hole area.
 This corresponds to a value of β = Ahole/Aactive of
6% to 25%.
 The average value of β is between 7% and 16%,
with 10% a reasonable first guess.
 The value of β is selected so that the vapor velocity
through the holes, vo, lies between the weep point
and the maximum velocity.

Dra. Nancy Elizabeth Dávila Guzmán

+ 93

Sieve Tray Layout and Tray

Hydraulics
The choice of material for the fabrication of trays is
dependent mainly on the corrosion properties of the
process fluids. In general, tray thickness is about
gauge 10 (0.134 in; 3.40 mm) for carbon steel and
gauge 12 (0.109 in; 2.77 mm) for stainless steel. For
economic reasons the holes are punched, which
dictates that the thickness must be less than the hole
diameter.

Dra. Nancy Elizabeth Dávila Guzmán

+ 94

Sieve Tray Layout and Tray

Hydraulics
Small holes with a diameter in the range of 3/16 to
1/4 in (4.76- 6.35 mm) give better hydraulic and
mass transfer performance than the large ones in the
range of 12 to 34 in (12.7- 19.0 mm). However, large-
hole trays are cheaper and show more resistance to
fouling. Choose the hole size according to design
requirements.

Dra. Nancy Elizabeth Dávila Guzmán

+ 95

Sieve Tray Layout and Tray

Hydraulics
 The vapor velocity through the holes, vo, in ft/s.

V MVV V is the lbmol/h of vapor

vo = ρv is the vapor density in lb/ft3
3600 rV Ahole
Ahole is the total hole area on the tray, ft2

æ do2 ö
Ahole = ( No. of holes) ç p ÷ Ahole = b Aactive
è 4ø

Dra. Nancy Elizabeth Dávila Guzmán

+ 96

Sieve Tray Layout and Tray

Hydraulics
V MVV
vo =
3600 rV Ahole
æ do2 ö Ahole = b Aactive
Ahole = ( No. of holes) ç p ÷
è 4ø

Aactive = Atotal (2h -1)

æ Di 2 ö
Atotal = çp ÷
è 4 ø

Dra. Nancy Elizabeth Dávila Guzmán

+ 97

Sieve Tray Layout and Tray

Hydraulics

1 2
Ad = r (q - sinq )
2
Ad = (1- h) Atotal
+ 98

Sieve Tray Layout and Tray

Hydraulics

Typically the ratio of lw/Di falls

in the range of 0.6 to 0.75

h 0.8 0.825 0.85 0.875 0.90 0.925 0.95 0.975

lw/Di 0.871 0.843 0.811 0.773 0.726 0.669 0.593 0.478

+ 99

Sieve Tray Layout and Tray

Hydraulics
Downcomers are designed on the basis of pressure drop
and liquid residence time.

hdc = hDp,dry + hw + hcrest + hgrad + hdu

+ 100

Sieve Tray Layout and Tray

Hydraulics
The head of liquid required to overcome the
pressure drop of gas on a dry tray, hΔp,dry:
æ rwater ö
hDp,dry = 0.003v rv ç ÷ (1- b ) / Co
2 2 2
inches
è rL ø
o

The orifice coefficient, Co, can be determined from value

The minimum
the
ttray is correlation of Hughmark and O’Connell:
the tray thickness for do/ttray is 1.0
æd ö
2
do
Co = 0.85032 - 0.04231 + 0.0017954 çç o ÷÷
ttray è ttray ø

Dra. Nancy Elizabeth Dávila Guzmán

+ 101

Sieve Tray Layout and Tray

Hydraulics
The minimum weir height is 0.5 inch with 2 to 4 inches
more common. 2
æ Lg ö 3
hcrest = 0.092Fweir ç ÷ inches
è lweir ø
Lg is the liquid flow rate in gal/min that is due to both L
and e (entrainment).
YL
e=
1- Y
Usually, entrainment is not a problem until fractional
entrainment is above 0.1.
Dra. Nancy Elizabeth Dávila Guzmán
+ 102

Dra. Nancy Elizabeth Dávila Guzmán

+ 103

Sieve Tray Layout and Tray

Hydraulics
2
æ Lg ö 3
hcrest = 0.092Fweir ç ÷ inches
è lweir ø
Lg is the liquid flow rate in gal/min that is due to both L
and e. Lweir in ft.

Fweir is a modification factor to take into account the

curvature of the column wall in the downcomer.

Dra. Nancy Elizabeth Dávila Guzmán

+ 104

Dra. Nancy Elizabeth Dávila Guzmán

+ 105

Sieve Tray Layout and Tray

Hydraulics
There is a frictional loss due to flow in the downcomer
and under the downcomer onto the tray, hdu
æ L ö2
hdu = 0.56 çç g
A
÷
÷ inches
è 449 du ø

Adu is the flow area under the downcomer apron in ft2.

Adu = ( gap) lw
The downcomer apron typically has a 1-in gap above
the tray.
Dra. Nancy Elizabeth Dávila Guzmán
+ 106

Sieve Tray Layout and Tray Hydraulics

In an operating distillation column the liquid in the

downcomer is aerated. The density of this aerated liquid
will be less than that of clear liquid, hdc,aerated:

hdc
hdc,aerated =
fdc inches

where φdc is the relative froth density. For normal

operation, a value of φdc = 0.5 is satisfactory.

To avoid downcomer flooding, the tray spacing

must be greater than hdc,aerated.

Dra. Nancy Elizabeth Dávila Guzmán

 107

Dra. Nancy Elizabeth Dávila Guzmán

+ 108

Sieve Tray Layout and Tray

Hydraulics
The downcomer is designed to give a liquid residence
time of three to seven seconds.

Ad hdc (3600) r L
tres = s
12 ( L + e) MW L

Foaming Tendency Examples tres (s)

Low Alcohols, low-MW hydrocarbons 3
Medium Medium-MW hydrocarbons 4
High Mineral oil absorbers 5
Very high Amines, glycols 7

Dra. Nancy Elizabeth Dávila Guzmán

+ 109

Sieve Tray Layout and Tray

Hydraulics
Liquid will not drain through the holes as long as the sum
of heads due to surface tension, hσ, and gas flow, hΔp,dry,
are greater than a function depending on the liquid head.

hDp,dry + hs ³ 0.10392 + 0.25119x - 0.021675x 2

where x = hweir + hcrest + hgrad.

The surface tension head hσ can be estimated from:

0.040s where σ is in dynes/cm,

hs = ρL in lb/ft3,
r L do d0 in inches
hσ in inches of liquid
Dra. Nancy Elizabeth Dávila Guzmán
+ 110

Tray layout and hydraulics

Determine the tray layout and pressure drops for a sieve-

plate distillation column which is separating a feed that is
50% mole % n-hexane and 50% mole %n-heptane. Feed is
a saturated liquid. Plate spacing is 24 in. Average column
pressure is 1 atm. Distillate composition is xD=0.9999
(mole fraction n-hexane) and xB=0.001. Feed rate is 1000
lbmol/h. Internal reflux ratio L/V = 0.8. The column has a
total reboiler and a total condenser. Determine if
entrainment or weeping is a problem. Determine if the
downcomers will work properly. Do these calculations
only at the top of the column.

Dra. Nancy Elizabeth Dávila Guzmán