Distillation Column Design

Nomenclature:

vapH Average Latent heat

T bL Boiling point of Aniline

T bH Boiling point of Nitrobenzene

Tb Mean boiling point

R Gas constant
Relative volatility

D Distillate molar flow rate

W Waste molar flow rate
F Feed molar flow rate
Rmin Minimum Reflux ratio

Ractual Actual Reflux ratio

L Molar liquid flow rate

V Molar vapor flow rate
H fs Enthalpy of one mole of feed at its boiling point

Latent Heat
Hf Enthalpy per mole of feed

N Theoretical number of trays

Nactual Actual number of trays
 Mean viscosity

EO Efficiency
Nr Number of plates above the feed, including any partial condenser
Ns Number of plates below the feed, including the boiler
x,hk Mole fraction of the heavy key in the feed
xf,lk Mole fraction of the heavy key in the feed
xd,lk Mole fraction of the light key in the distillate product
xd,hk Mole fraction of the heavy key in the distillate product
xb,lk Mole fraction of the light key in the bottom product
xb,hk Mole fraction of the heavy key in the bottom product
Ac Total column cross-sectional area
Ad Down comer cross-sectional area
An Net cross sectional area
Aa Active area
Ah Hole area
Ap Perforated area
Aap Clearance area under down comer apron
K1 Constant obtained from figure 11.27 [6]
uf Flooding vapor velocity
v Vapor density
l Liquid density
Fractional entrainment
FLV Liquid vapor flow factor
K2 Constant obtained from figure 11.29 [6]
Dh Hole diameter
uh Minimum design vapor velocity
lw Weir length
how Weir crest
Lw Liquid flow rate
hd Dry plate drop
Co Orifice coefficient
Delta Pt Total pressure drop
ht Total plate pressure drop
hr Residual head
tr Residence time
hbc Clear liquid backup
 Distillation Tower Design
Feed = 388.704961 Kmol/hr
Components Molar Composition Molar Flow rates (Kmol/hr)
Aniline 0.979535926 380.7504738
Nitrobenzene 0.020464074 7.954487243
Distillate =
380.0651856 Kmol/hr
Components Molar Composition Molar Flow rates (Kmol/hr)
Aniline 0.999998486 380.06461
Nitrobenzene 1.51448E-06 0.0005756

Bottom = 8.639775443 Kmol/hr

Components Molar Composition Molar Flow rates (Kmol/hr)
Aniline
0.079384447 0.685863800
Nitrobenzene
0.920615553 7.953911643

Calculation of Average relative volatility using Clausius-Clapeyron equation: [22]

vapH T bH T bL

=e
( R . Tb
.
Tb )

Latent heat of Aniline = 44220 J.mol.K [7]

Latent heat of Nitrobenzene = 44080 J/mol.K [7]

Average Latent heat= vapH =44217.13503 J/mol.K

T bL
Boiling point of Aniline= = 457 K

T bH
Boiling point of Nitrobenzene= = 484 K
 Tb T bHT bL
Mean boiling point= = = 470.3062832 K

Gas constant =R= 8.314 J/mol.K

vapH T bH T bL

=e
( R . Tb
.
Tb )

= 1.914021229

Minimum Reflux: [23]

1 XdA ( 1 XdA )
Rmin .( )
= ( 1 ) XfA ( 1XfA )

1 0.999848501 ( 10.999848501)
Rmin .( ( 1.914021229 ) )
= ( 1.9140212291 ) 0.979535926 ( 10.979535926 )

Rmin = 1.116766627

Reflux ratio is 1.1-1.5 times the minimum reflux ratio. (Richardson, Harkar, & Backhurst, 2002)
Ractual = 1.5*Rm

Ractual = 1.675149941

Top and Bottom operating Line data: [23]

Ln R Actual
= *D
Ln = 636.6661733 kmol/hr

Vn Ln
= +D

Vn = 1016.7313589107600 Kmol/hr

Lm Ln
= +F
Lm =1025.371134 kmol/hr
 Vm Lm
= W

Vm =1016.7313589107600 kmol/hr

Top operating line [23 ]

ln D
yn . x n+1 + . xd
= Vn Vn

yn x n+1
= 0.626189177 + 0.373810256

Bottom Operating line: [23]

W

ym Lm
= Vm x w

Vmx m +1

y m = 1.008497599 x - 0.000674577
m+1

Q-line Calculation: [23]

Feed is coming at 453.1 K

Boiling point of feed = 457.8197069 K

q Xf
yq xq
= q1 q1

+ H fs H f
q=

H fs = Enthalpy of one mole of feed at its boiling point = 30700 KJ/mol

= Latent Heat = 44217.13503 KJ/Kmol

H f = Enthalpy per mole of feed = 29800 KJ/Kmol

+ H fs H f
q= = 1.0203541
 q Xf
yq xq
= q1 q1

yq xq
= 50.13015003 - 48.12474699

Vapor Liquid Equilibrium Data: [18]

x a
ya
= 1+ ( 1 )x a

Xa Ya
Liquid fraction ( ) Assumed Vapor fraction ( ) Calculated
0 0
0.05 0.091518566
0.10 0.175372687
0.15 0.252486483
0.20 0.323641251
0.25 0.389502027
0.30 0.450638439
0.35 0.507541222
0.40 0.560635421
0.45 0.610291025
0.50 0.656831601
0.55 0.700541357
0.60 0.741670944
0.65 0.780442274
0.70 0.817052518
0.75 0.851677462
0.80 0.884474331
0.85 0.915584177
0.90 0.945133901
0.95 0.973237992
1.0 1
Plotting Top Operating Line, Bottom Operating Line , Q-line and Vapor-Liquid
Equilibrium Data on Excel sheet to Calculate the Number of theoretical plates
required in the Distillation Column using McCabe-thiele Method.
 1

0.9

Mole fraction in Vapor phase (Y)

0.8

0.7

0.6 Mole fraction in liquid phase (X)

0.5

0.4

0.3

0.2

0.1

0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
No of theoretical stages =17
OConnel Correlation: [6]
Bubble point of feed = 457.8197069 K
Dew point of top = 456.9 K
Bubble point of bottom = 481.7 K
Average column temperature = (456.9 + 481.7)/2 = 469.3 K
Viscosity of Aniline at 469.3 K = 0.2 CP (Kern, 1965)
Viscosity of Nitrobenzene at 469.3 K = 0.4 CP (Kern, 1965)

Mean viscosity at 469.3 K = = 0.204092815 CP

Efficiency = Eo = 51-32.5* log ( . )

Eo= 0.642673299 = 64.2673299 %

No of actual plates required = theoretical number of plates/ Efficiency

No of actual plates required =17/ 0.642673299 = 26.45200919 = 27

(Coulson and Richardson Vol.6 (eq11.67))

Kirkbride (Feed point location): [6]
Nr B xf , hk xb , lk 2
log
Ns
=0.206 log(
D
.( )(
xf , lk
.)(
xd , hk ) )

Nr
Log Ns = 01.259805682

Nr
Ns = 18.18886846

Nr Ns
+ = 27

N r = 25.59293423
 N s = 1.407065771

th
Feed plate = 2

Column mechanical Design:

Top:
Flooding velocity: [6]
3
Vapor density at top = 2.483 kg/ m [16]

3
Liquid density at top = 872.7 kg/ m 16]

Surface tension = 24.13 dyn/cm [16]

Liquid vapor flow factor =

Lw v
.
Vw L
Lw/Vw (slope) = 0.626189177
Liquid vapor flow factor = 0.033401151
Assumed plate spacing = 0.70m [6]
Using fig 11.27 [6]
K 1 = 0.12 * 1.038258428

K 1 = 0.124591011

Flooding velocity =
K1
* l v
v

Flooding velocity = 2.332448874 m/s

Superficial vapor velocity: [6]
Design for 85 % of the flooding velocity.
Superficial vapor velocity = 0.85 * flooding velocity
Superficial vapor velocity = 1.982581543 m/s
V n = 1016.7313589107600 Kmol/hr

VnMol weight
Volumetric flow rate = v3600
3
Volumetric flow rate = 10.59294217 m /sec

Net area: [6]

V . F. R
Net area = Max vap velocity

2
Net area = 5.343004531 m

Column area: [6]

N et area
Column area = 0.88

2
Column area = 6.071596058 m

Column diameter = Ac4/

Column diameter = 2.781100011 m

Bottom:
Flooding velocity: [6]
3
Vapor density at top = 3.013 kg/ m [16]

3
Liquid density at top = 988.6 kg/ m [16]

Surface tension = 38.43 dyn/cm [16]

Liquid vapor flow factor = .

Lw v
Vw L

Lw/Vw (slope) = 1.008497599

Liquid vapor flow factor = 0.055675501
Using fig 11.27 [6]
K 1 = 0.117 * 1.139536073

K 1 = 0.133325721

Flooding velocity = K1* l v

v [6]

Flooding velocity = 2.411358914 m/s

(Coulson and Richardson Vol.6 (eq11.81))
Design for 85 % of the flooding velocity [6]
Superficial vapor velocity = 0.85 * flooding velocity
Superficial vapor velocity = 2.049655077 m/s
Vm = 1016.7313589107600 Kmol/hr
VnMol weight
Volumetric flow rate = v3600
3
Volumetric flow rate = 11.53510354 m /sec

Net area: [6]

V . F. R
Net area = Max vap velocity

2
Net area = 5.627826684 m

Column area: [6]

Net area
Column area = 0.88
 2
Column area = 6.395257596 m

Column diameter: [6]

Column diameter = Ac4/

Column diameter = 2.854264347 m or 112.3438447 inch

Plate Design: [6]
dc
Diameter of column = = 2.854264347 m

Ac 2
Area of column = = 6.395258 m

Ad 2
Down comer area = = 0.12 *6.395258 = 0.767431 m

Ac Ad 2
Net area = - = 5.627827 m

Ac Ad 2
Active area or perforated area = -2* = 4.860396 m

Hole area is the 10% of the active area as first trial. [6]
2
Hole area = 0.48604 m

Ad Ac
( / )*100 = 12

Using figure 11.31, we find [6]

l w /d c = 0.76

lw
Weir length = = 2.169241 m

Assumed values are [6]

Weir height = 50 mm
Hole diameter = 5 mm
Plate thickness = 5 mm
Plate spacing = 0.7 m
Height of column = 1.2*(plate spacing + plate thickness) * No of plates =1.2* (0.70+0.005)*27
=22.842m = 74.92176 ft
Height of column is less than 165 ft, so height of column is satisfactory.
H/D of the column = 22.842/2.854264 = 8.002763
H/D is less than 30 so, its acceptable.
Check weeping:
LmMol weight
Lw
Maximum liquid rate = = 3600

Lw
Maximum liquid rate= = 35.0506 kg/sec

Lw
Minimum liquid rate = = 0.7*max liquid rate = 24.53542 Kg/sec

Maximum weir crest =

how
= 750
0.67 Lw
llw = 49.64592 mm liquid

(C&R vol 6 (eq11.85))

Minimum weir crest =

how
= 750
0.67 Lw
llw = 39.23271 mm liquid

hw how
Minimum rate = ( + ) = 89.23271 mm liquid

K2
Using fig 11.30, we find [6]

K 2 = 30.8

(K 20.90 ( 25.4dh ) )
uh
Minimum vapor velocity = = v 0.5

Minimum vapor velocity = 7.166726 m/s

Actual minimum vapor velocity = (V . F . R of bottom0.7)/ Ah

Actual minimum vapor velocity = 16.61299 m/s

Minimum operating rate will be above weep point.
Plate pressure drop: [6]

Maximum vapor velocity through holes = (V . F . R of bottom)/ Ah

Maximum vapor velocity through holes = 23.73285 m/s
Plate thickness/ hole diameter = 1
Ah Ap
( / )*100 = 10

Co
Using fig 11.34, to find [6]

Co
Orifice coefficient = = 0.84

Dry pressure drop =

hd
= 51* ( ) vL
uh
Co

Dry pressure drop = 124.0766 mm liquid

12.51000
hr
Residual head = = L = 12.64414 mm liquid

ht hd hr hw hwo
Total pressure drop = = + + + = 236.3667 mm liquid

(Coulson and Richardson Vol.6 (eq11.88, 11.89, 11.90))

Downcomer pressure loss: [6]
hw
Hap = -10 = 40 mm

Lw hap
Area under apron = *

A ap 2
Area under apron = =0.086769636 m

2
Lwd
Head loss in down comer =
hdc
= 166* ( L. Am )
Head loss in down comer = 27.71547446 mm
hb hw hwo ht hdc
Backup in down comer = = + + +

hb
Backup in down comer = = 0.363728047 m

Acceptable because its less than 0.375 (1/2(plate spacing + weir height))
(Coulson and Richardson Vol.6 (eq11.91, 11.92))
Residence Time: [6]
Adhbcl
Tr
Residence time = = Lwd = 7.873016974 sec

Acceptable because its is greater than 3 seconds.

(Coulson and Richardson Vol.6 (11.92))

Check entrainment: [6]

Uv = V.F.R of bottom /active area = 2.049655077 m/s

Check flooding percentage: [6]

Uv
Percentage flooding = /bottom flooding velocity = 0.85 = 85%

Using fig 11.29[6]

= Fractional entrainment = 0.06 < 0.1 [6]
The effect on efficiency will be small.
Perforated area: [6]
l w /d c = 0.76

= 99 degree [6]
Angle subtended = 180 =81 degree
l w /d c
Mean length, unperforated = ( 0.05) *81/180 = 3.962425522 m

Area of unperforated edge strip = 0.05 * mean length = 0.198121276 m2

Mean length of calming zone = 0.05 + weir length = 2.219240904 m

Area of calming zone = 2* (Mean length of calming zone*0.05) = 0.22192409 m2

Ac
Area of total perforation = - area of c.z area of unperforated edge = 4.440350406
m2

Ah/Ap = 0.109459735
From fig 11.33 [6]
Lp/Lh = 2.8
Satistactory, within 2.5-4.0
Number of holes: [6]
2
Area of one hole = 0.00001964 m

Ah
Number of holes = /Area of one hole = 24747.43265

= 24748
Pressure: [6]
Top pressure = 101325 Pa = 1 atm
ht l
Estimated pressure drop in bottom = N*9.81*0.001* * = 61892.72 pa

Estimated pressure drop in bottom = 0.610833676 atm

Actual bottom pressure = 101325+61892.72 = 163217.7 Pa =1.610833676atm
(C&R vol6 (eq11.87))
Wall thickness: [10]
Cylindrical shell:
Ej
P <= 0.385*(S* )

101 KPa <= 27,064 KPa

So we use this equation
Pr i
t= +C C
SE j0.6P

r = 1.427132 m
P = 101KPa
S = 82700 KPa
E j = 0.85

CC = 4 mm = 0.004 m
 Pr i
t= +C C
SE j0.6P

Thickness = 0.006059mm
Thickness = 6.058885 m

Specification sheet:

Equipment Distillation column

Actual No. of Trays 27

Feed plate 2
Efficiency 64.2673299%

Reflux Ratio 1.675149941

Top Diameter 2.781100011 m

Bottom Diameter 2.854264347 m

Height of Column 22.77257143 m

No. of Holes 24748

Superficial Velocity 85% of flooding velocity

Pressure Drop 236.3667 mm liquid

Plate Thickness 0.005 m

Plate Spacing 0.70 m

Wall Thickness 6.058885 mm

Proposed Design: (Coulson and Richardson Vol.6)
50 mm

2.85 m 2.17m

50 mm

40 mm
50 mm
22.773 m

Cost estimation: [6]

Vessel cost:

By using figure 6.5b, we get (C&R Vol 6 fig 6.5b)

Purchased cost = (bare cost from figure)*(material factor) *(pressure factor)

Purchased cost = $100000 * 1 * 1

Purchased cost = $100000

Plates cost:

By using figure 6.7b (C&R Vol 6 fig 6.7b)

Plates cost = (cost from figure * Material factor)* no of plates

Plates cost = $900*1*27

Plates cost = $27300

Total cost = Vessel cost + Plates cost

Total cost = $100000 + $27300

Total cost = $127300

Figures: