Determination of Reflux Ratio

Using Underwood Equation,

ixi,d /(i - ) = Rm + 1 Ref : Eqn 11.28, Page 711, Sinnott &Towler,
Volume 6, 5th Ed.
where is the root of the equation
ixi,f /(i - ) = 1-q Ref : Eqn 11.29, Page 711, Sinnott &Towler, Volume
6, 5th Ed.
On solving, Rmin = 0.6722
Actual R = 1.2* Rmin = 1.0084

Determination of Number of Stages

Nm = log (xlkd/xhkd)(xhkb/xlkb) / log (lk) Ref : Eqn 11.26, Page 710, Sinnott
&Towler, Volume 6, 5th
Nm = 17
Rm / (Rm +1) = 0.4
R / (R+1) = 0.5
Using fig 11.11 Erbar- Maddox correlation, Page 710, Sinnott &Towler,
Volume 6, 5th Ed.
Nm /N = 0.6
N = 17/0.6 = 28.33 = 29
Plate Efficiency = 0.7
So, the actual no. of plates = 29/ 0.7 = 41.43 = 42

Determination of Feed Point Location

log (Nr/Ns) = 0.206 log [(B/D)(xfhk/xflk )(xblk/xdhk)(xbhk/xdhk) ]

= -0.1844
Nr/Ns = 0.654
But, N = Nr + Ns = 28.33
Nr = 11.2
Actual location of feed plate = 11.2/0.7 = 16th plate from top.

*These values were used to simulate the data in AspenPlus.

The results obtained were tabulated in the in table under
product specifications. The heat duty of the condenser and
reboiler are contained in the table below.

4.) Determination of Column Diameter and Height

Height of Column:
Taking tray spacing = 0.5, we get;
Column Height = Actual number of plates * Tray Spacing = 0.5* 42 =
21 m

Assumed Pressure Drop: 100 mm water / plate

Total Pressure Drop = 20.6 kPa = 0.206 bar
Estimated Pressure at bottom = 1.938 atm
Bottom: v = 1.07 kg/m3 L = 988 kg/m3
Molecular Wt. = 18.02 Surface tension = 57.7 * 10-3 N/m
Top : v = 1.81 kg/m3 L = 803 kg/m3
Moelcular Wt. = 42 Surface Tension = 26.34 * 10-3 N/m
Bottom Flv = 0.185165551 Ref : Eqn 11.50,
Top Flv = 0.082764495 Ref : Eqn 11.50,

Calculation of flooding velocity

Assumed tray spacing = 0.5

Uf = k1(L - v / v)0.5

Where, Uf = flooding velocity in m/s

K1 = constant From Appendix B figure 10

Top K1=0.085

Bottom K1=0.075

Correction for surface tension: K1 = K1 [/0.02]0.2

Where is in N/m

Top K1=0.090

Bottom K1=0.0927

Top Uf = 1.893 m/s

Bottom Uf = 2.815 m/s

Assuming 90% flooding,

U (top)= 0.9*1.893 = 1.704 m/s

U (bottom) = 0.9* 2.815 = 2.533 m/s

Maximum volumetric flow rate of vapors = mV = mass vapor flow rate/
(3600 vapor density) = 0.278 m3 / s (Top)

mv = 0.793 m3 / s (Bottom)

Net area required = An = mv/ U =0.299 m2 (Top)

An = 0.602 m2 (Bottom)

Assume that downcomers occupies 15% of cross sectional Area (Ac) of

column.

Ac = An + Ad

Where, Ad = downcomer area

Ac = An + 0.15(Ac)

Ac = An / 0.85

Ac =0.3514 m2 (Top)

Ac =0.7088 m2 (Bottom)

Ac =(/4)D2

D = (4 Ac /)1/2

D = 0.6689 meter (Top)

D = 0.9500 meter (Bottom)

Since bottom diameter is larger so calculations will be based on bottom

conditions.

Liquid flow arrangement

Maximum liquid flow rate = (Liquid mass rate)/ (3600) (Liquid density)

Max Liquid Rate is at the bottom of column

So, Maximum liquid flow rate = 0.0030 m /s3

From Appendix B figure 11, cross flow single pass plate is selected.
Provisional Plate Design
Column Diameter Dc = 0.95 m

Column Cross-sectional Area (Ac)= 0.709 m2

Down comer area Ad = 0.15Ac = 0.1064 m2

Net Area (An) = Ac Ad =0.603 m2

Active area Aa = Ac - 2Ad = 0.497 m2

Hole area Ah take 6% Aa = 0.06 0.232 = 0.0298 m2

Weir length
Ad / Ac = 0.2064 / 0.709 = 0.1501

From Appendix B figure 13,

Lw / dc = 0.81

Lw = 0.95*0.81= 0.7695 m

Weir length should be 60 to 85% of column diameter which is

satisfactory.

Take weir height, hw = 50 mm

Hole diameter, dh = 5 mm

Plate thickness = 5 mm (Carbon Steel)

Check Weeping
Uh(min) = [K2-0.9(25.4-dh)]/ v0.5
Where Uh(min) is the minimum design vapor velocity.

The vapor velocity at weeping point is the minimum velocity for the
stable operation. In order to have K2 value we have to 1st find how
(depth of the crest of liquid over the weir)

Where how is calculated by following formula:

how(max) = 750 (Lm/ LLw)2/3

Taking minimum liquid rate at 70% turn down ratio of maximum liquid
rate
At Maximum rate (how) = 18.73 mm Liquid

At Minimum rate (how) = 14.76 mm Liquid

hw + how = 50 + 14.76 = 64.76 mm Liquid

From Appendix B figure 12,

K2 = 30.5

So, U (min) = 7.39 m/s

Now taking maximum volumetric flow rate (vapors) at 70% turn down
ratio

Actual minimum vapor velocity =minimum vapor rate / Ah

= 10.56 m/s

So, minimum vapor rate will be well above the weep point.

Plate Pressure Drop (P.D)

Consists of

Dry plate P.D (orifice loss)

P.D due to static head of liquid and
Residual P.D (bubbles formation result in energy loss + froth
formed in operating plates)

Dry Plate Drop

Max. Vapor velocity through holes (Uh) = 14.38 m/sec
Active Area = Aa = 0.497 m2
Ah/Aa = 0.06
From Appendix B fig. 14, Co = 0.81
hd = 51(Uh / Co)2 (v / L)
= 20.89 mm liquid

Residual Drop
hr = 12.5 1000 / L
= 15.18 mm liquid

Total Plate Pressure Drop

ht = hd + hr + (hw +how)
= 113.78 mm liquid
T-102

Determination of Reflux Ratio

Using Underwood Equation,
ixi,d/(i - ) = Rm + 1 Ref : Eqn 11.28, Page 711, Sinnott &Towler,
Volume 6, 5th Ed.
where is the root of the equation
ixi,f/(i - ) = 1-q Ref : Eqn 11.29, Page 711, Sinnott &Towler,
Volume 6, 5th Ed.
On solving, Rmin = 0.752
Actual R = 1.5*Rmin = 1.127

Determination of Number of Stages

Nm = log (xlkd/xhkd)(xhkb/xlkb) / log (lk) Ref : Eqn 11.26, Page 710,
Sinnott &Towler, Volume 6, 5th
Nm = 17
Rm / (Rm +1) = .047
R/ (R+1) = 0.53
Using fig 11.11 Erbar - Maddox correlation, Page 710, Sinnott &Towler,
Volume 6, 5th Ed.
Nm /N = 0.58
N = 17/0.58 = 29.31 = 30
Plate Efficiency = 0.7
So the actual no. of plates = 30/ 0.7 = 42.86 = 43

Determination of Feed Point Location

Log (Nr/Ns) = 0.206 log [(B/D)(xfhk/xflk)(xblk/xdhk)(xblk/xdhk) ]

= -0.1226
Nr/Ns = 0.754
But N = Nr + Ns = 29.31
Nr = 12.6
Actual location of feed plate = 12.6/0.7 = 18th plate from top.

*These values were used to simulate the data in AspenPlus.

The results obtained were tabulated in the in table under
product specifications. The heat duty of the condenser and
reboiler are contained in the table below.
4.) Determination of Column Diameter and Height

Height of Column:
Taking tray spacing = 0.5, we get;
Column Height = Actual number of plates * Tray Spacing = 0.5* 43 =
21.5 m

Assumed Pressure Drop: 100 mm water / plate

Total Pressure Drop = 21.09 kPa = 0.211 bar
Estimated Pressure at bottom = 1.208 atm
Bottom: pv = 1.07 kg/m3 pl = 988 kg/m3
Molecular Wt. = 18.02 Surface tension = 57.7 * 10-3 N/m
Top : pv = 1.81 kg/m3 pl= 803 kg/m3
Moelcular Wt. = 42 Surface Tension = 26.34 * 10-3 N/m
Bottom Flv = 0.19306 Ref : Eqn 11.50,
Top Flv = 0.09271247 Ref : Eqn 11.50,

Calculation of flooding velocity

Assumed tray spacing = 0.5

Uf = k1(pL -pV/pV)0.5

Where, Uf = flooding velocity in m/sec

K1= constant From Appendix B figure 10

Top K1=0.0825

Bottom K1=0.0725

Correction for surface tension K1 [/0.02]0.2

Where in N/m

Top K1=0.0872

Bottom K1=0.0896

Top Uf = 1.736 m/sec

Bottom Uf = 2.202 m/sec

Assuming 90% flooding,

U (top)= 0.9*1.736 = 1.562 m/s

U (bottom) = 0.9* 2.202 = 1.982 m/s

Maximum volumetric flow rate of vapors = mv = mass vapor flow rate /

(3600) vapor density)

= 0.249 m3 / s (Top)

Mv = 0.657 m3 / s (Bottom)

Net area required = An = mv/ U =0.143 m2 (Top)

An= 0.298 m2 (Bottom)

Assume that downcomers occupies 15% of cross sectional Area (Ac) of

column.

Ac = An + Ad

Where, Ad = downcomer area

Ac = An + 0.15(Ac)

Ac = An / 0.85

Ac=0.168 m2 (Top)

Ac=0.350 m2 (Bottom)

Ac =(/4)D2

D = (4Ac/)1/2

D = 0.7731 meter (Top)

D = 1.0125 meter (Bottom)

Since bottom diameter is larger so calculations will be based on bottom

conditions.

Liquid flow arrangement

Maximum liquid flow rate = (Liquid mass rate)/ (3600) (Liquid density)

Max Liquid Rate is at the bottom of column

So, Maximum liquid flow rate = 0.0033 m3/sec

From Appendix B figure 11, cross flow single pass plate is selected.

Provisional Plate Design

Column Diameter Dc= 1.0125 m

Column Cross-sectional Area (Ac)= 0.805 m2

Down comer area Ad = 0.15Ac = 0.121 m2

Net Area (An) = Ac - Ad =0.684 m2

Active area Aa=Ac-2Ad = 0.563 m2

Hole area Ah take 6% Aa = 0.06 0.563 = 0.034 m2

Weir length
Ad / Ac = 0.2064 / 0.709 = 0.15

From Appendix B figure 13,

Lw / dc = 0.81

Lw = 1.0125*0.81= 0.82 m

Weir length should be 60 to 85% of column diameter which is satisfactory.

Take weir height, hw = 50 mm

Hole diameter, dh = 5 mm

Plate thickness = 5 mm (Carbon Steel)

Check Weeping

Uh(min) = [K2-0.9(25.4-dh)]/ pv 0.5

Where Uh(min) is the minimum design vapor velocity.

The vapor velocity at weeping point is the minimum velocity for the stable
operation. In order to have K2 value we have to 1st find how (depth of the
crest of liquid over the weir)

Where how is calculated by following formula:

how(max) = 750 (Lm/pLLw)2/3

Taking minimum liquid rate at 70% turn down ratio of maximum liquid rate

At Maximum rate (how) = 19.13 mm Liquid

At Minimum rate (how) = 15.08 mm Liquid

hw + how = 50 + 15.08 = 65.08 mm Liquid

From Appendix B figure 12,

K2 = 30.4

So, U (min) = 7.29 m/sec

Now taking maximum volumetric flow rate (vapors) at 70% turn down ratio

Actual minimum vapor velocity =minimum vapor rate / Ah

= 10.42 m/sec

So, minimum vapor rate will be well above the weep point.

Plate Pressure Drop (P.D)

Consists of

Dry plate P.D (orifice loss)

P.D due to static head of liquid and
Residual P.D (bubbles formation result in energy loss + froth formed in operating plates)

Dry Plate Drop

Max. Vapor velocity through holes (Uh) = 14.38 m/sec
Active Area = Aa = 0.497 m2
Ah/Aa = 0.06
From Appendix B figure 14, C0 = 0.81
hd = 51(Uh / Co)2 (pv / pL)
= 23.48 mm liquid

Residual Drop
hr = 12.5 1000 / pL
= 17.06 mm liquid

Total Plate Pressure Drop

ht = hd + hr + (hw +how)
= 113.78 mm liquid
Design Calculations of Distillation Column (T-103)

From Mass Flow Rate Molar Flow Rate Mass Fraction

material (Kg/hr) (Kgmol/hr)
balance Feed
Composition
& Flow Rates
(F) Component
Acrolein 146.64 2.618 0.64100
Propylene 0.0304 0.0007 0.0001332
Water 82.09 4.561 0.35886

Bottom Mass Flow Rate Molar Flow Mass Fraction

Product (Kg/hr) Rate(Kgmol/hr)
Composition
& Flow Rates
(B) Component
Acrolein 3687.57 65.8495 .85
Propylene 8.001 0.1905 .0018
Water 643.509 35.7505 .1482

Bottom Temperature (TB)

Bubble point calculations
PT = 130 kpa T=105 oC (Assume)
Components Xb=Xi Ki Yi= KiXi
Acrolein 0.85 3.5475 0.0333
Water 0.1482 1.0094 0.9999
Propylene .0018
Total 1.03

Top Temperature (TD)

Dew point calculations
PT = 101.325kpa T=52 oC (Assume)

Design Calculations
Design Calculations
Inlet Composition of Gases (Yb) Amounts in Kg-mole
Acrolein 64.6938

Propylene 45.0342

Acrylic acid 13.2016

Nitrogen 661.797

Carbon di-oxide 42.6339

Oxygen 13.20165

Water 32181.74

The Total Flow rate of gases From reactor is 33040.64 Kg-mole/hr.

Liquid Inlet (Xa) Amounts in Kg-mole

Water 32181

The Total Flow rate of water From De-ionized water source is 1800 Kg-mole/hr.

Top Product Composition (Ya ) Amounts in Kg-mole

Nitrogen 661.6827
Oxygen 31.4896
Carbon Di-oxide 42.5767
Acrolein 4.7434
Propylene 25.3746
Water 26.4

Bottom Product Compositions Amounts in Kg-mole

(Xb)
Acrolein 59.3217
Propylene 19.6596
Acrylic acid 0
Water 32155.45

Design Conditions
Basis : One Hour Operation
Iso-thermal operation (200 C and 1atm )
Its only Physical Absorption Process
92% Acrolein is absorbed
Absorbent is De-ionized Water
All Other gases are Inert Except Acrolein
 Some Specified quantity of Propylene is also Absorbed

Packed-column design procedure The design of a packed column will involve the
following steps:
Select the type and size of packing.
Determine the column height required for the specified separation. Determine the
column diameter (capacity), to handle the liquid and vapor flow rates.
Select and design the column internal features: packing support, liquid distributor,
redistributors.

The Henry Law Coefficient For Acrolein in water at 200 C is 8.2025 10-5 atm-m3/mole can
be converted to the slope of Equilibrium line in mole fraction units as

P =1atm

1 m3 weights 106g

m = 8.2025 10-5 atm-m3/mole 1/atm 106 mole H2O /18 m

m =4.55

And

Tan = 4.55

= tan-1 ( 4.55) =77.604

Height of Mass Transfer Zone

Z= Height of mass transfer zone

Hoy =Height of transfer units ,m
Noy=Number of transfer units
As
Z= Hoy Noy ----------------------------------------(1)

Calculation of Noy
Here Acrolein is Key Component and design will Be Based on this, Entering De-ionized
water is free of solute Ya =0
Now
Noy =A/A-1 [n (Yb/Ya)(A-1)+1/A]-------------(2)
As
A=L/mV
Here
Ya= mole Fraction of solute At Top in Gases
Yb= mole Fraction of solute At botom in Gases
m= Slope
L=Liquid Flow rate
V=Vapor Flow rate
Ya =15.3 Yb =187.4
L=5715 Kg-mole/hr
V= 33040.64 Kg-mole/hr
A=L/mV= 2.298
L/V= 10.459=Slope of Operating line

m =10.459

Tan =10.459

= Tan-1 (10.459) =2.382

By Putting the values in Equation No. 2

Noy =A/A-1 [n (Yb/Ya)(A-1)+1/A]-------------(2)

Noy =3.55

Calculation of Hoy
By using the Gas Film Basis

Hy=[V/S]/Kya------------------------------------------------------------(3)

Here

Kya =Overall Mass-transfer Coefficient Based on Gas Phase (Kg-mole/m 3-

sec)

V=Flow rate

S=Cross-Sectional area By Rule of Thumb

Kya(Unknown) =Kya (Known)(Dv Unknown/Dv Known) 0.56 ...............(4)

At 200 C Dv (unknown Acrolein)=0.4069 ft2/hr

Dv (known SO2)=0.448 ft2/hr

Kya (known SO2)=2 Kg-mole/ft3-hr-moles

By Putting the Values in above equation (4)

Kya(Unknown) =Kya (Known)( Dv Unknown/Dv Known) 0.56 ...............(4)

Kya(Unknown) =1.823 Kg-mole/ft3-hr-sec

Kya(Unknown) =0.0180 Kg-mole/m3-sec

Calculation of Cross-Sectional Area
As Flow Factor

Flv=Lw/Vw v/l------------------------------------------------(5)

L=1800Kgmole/hr

V=172.1kgmole/hr

By using Formula( For Gas) v =PM/RT-------------------(6)

v =0.775 Kg/m3

By using Formula( For Liquid)

l (water)= AB-(1-T/Tc)n......(7)

Where l (water)=998.20 Kg/m3

By Putting the values in Equation No.5

Flv=Lw/Vw v/l------------------------------------------------(5)

Flv=0.291

For Absorber /Stripper

For Random Packing , Pressure Drop will not normally exceed 80mm of
water/m of Packing.

For Absorber and stripper Range (15------50mm)

We consider flooding velocity as 80 %

We Consider 21mm and Flv=0. 0.291

By Using Appendix B figure 9

As can be calculated by using the formula

Percentage Flooding = [K4 at Design Pressure Drop/K4 at

Flooding]100----------(8)

Percentage Flooding = [ 0.5/ 0.8]100