6.

1 Distillation column design

The following series of tables summarise the compositions entering and leaving the distillation
column. These figures were calculated in Chapter 5, mass balance for distillation column 1.
Table 1: Inlet stream balance

Inlet
Stream FEED
Components kg/hr. kmol/hr. wt.%
Ethanol 295.29 6.42 11
Water 958.74 53.25 89
TOTAL 1254.03 59.67 100

Table 2: Outlet streams balance

Outlet
Stream DISTILLATE BOTTOMS
Component kg/hr. kmol/hr. wt% kg/hr. kmol/hr. wt%
Ethanol 292.38 6.36 84 2.76 0.06 0.1
Water 21.81 1.20 16 936.90 52.05 99.9
TOTAL 314.19 7.56 100 939.66 52.11 100

For the ethanol-water system, the Antoine constants are shown in the table below.

Table 3: Antoine constants

Component A B C B.P (°C)

Ethanol 8.1122 1592.864 226.184 78.4
Water 8.07131 1730.7 234.426 100

6.1.1 Relative volatility

The relative volatility is calculated to be 6.3
6.1.2 Minimum reflux ratio, Rmin
The minimum reflux ratio is calculated using the Underwood equation.

1 𝑥 𝛼𝐴𝐵 (1−𝑥𝐷 )
𝑅𝑚𝑖𝑛 = [𝛼 ]( 𝑥𝐷 − )
𝐴𝐵 −1 𝐹 1−𝑥𝐹

Where,
Rmin : minimum reflux ratio
αAB : relative volatility
xD : mole fraction of ethanol in distillate
xF : mole fraction of ethanol in feed

1 0.84 6.3(1−0.84)
𝑅𝑚𝑖𝑛 = [6.3−1](0.11 − )
1−0.11

= 1.23

6.1.3 Actual reflux ratio, R

R = 1.2Rmin
= 1.2×1.23
= 1.48

6.1.4 Number of theoretical plates

The Fenske Equation and Gilliland correlation are used together to calculate the number of
theoretical stages. The minimum number of stages at total reflux can be calculated using the
Fenske Equation. Estimation of the number of theoretical plates required then follows using
the Gilliland correlation.
Fenske equation
𝑥 𝑥
𝑙𝑜𝑔[( 𝐴 )𝐷 ( 𝐵 )𝑊 ]
𝑥𝐵 𝑥𝐴
(𝑛 + 1)𝑚 =
𝑙𝑜𝑔𝛼𝐴𝐵

Where,
αAB : relative volatility
xAB : mole fraction of ethanol in distillate
xBD : mole fraction of water in distillate
xBW : mole fraction of water in bottoms
 xAW : mole fraction of ethanol in bottoms

0.84 0.99
𝑙𝑜𝑔[( )( )]
0.16 0.01
(𝑛 + 1)𝑚 = 𝑙𝑜𝑔6.3

= 3.40

The Gilliland correlation can now be used to calculate the number of theoretical stages.

Figure 1: Gilliland correlation (Sinnot R K, 2002)

Calculating for x-axis

𝑅−𝑅𝑚 1.48−1.23
= = 0.112
𝑅+1 1.23+1

From the graph it can be determined that the curve is intersected at 0.51

(𝑛+1)−(𝑛𝑚 =1)
From the y-axis: 𝑛+2
(𝑛+1)−(3.40)
So, = 0.51
𝑛+2

Therefore,
n = 6.98 ≈ 7 stages
6.1.4 Internal traffic

DISTILATE
D
L

FEED
F

G’

W
BOTTOMS
L’

Figure 2: Internal traffic

The following equations are used to establish internal flowrates.

L = RD
L’ = RD+F
G’ =G
= RD+D
Where,
L : Liquid flow rate in the top section
G’ : Vapor flow rate in the column

L’ : Liquid flow rate in the bottom section

Table 4: Internal traffic

Flow Mass flowrate (kg/hr.) Molar flowrate (kmol/hr.)

L 465.00 11.19
L’ 1719.03 70.86
G’ 779.19 18.75
G 779.19 18.75
6.1.5 Vapour density
Assumptions
 Column is operating at atmospheric pressure.

Using the ideal gas equation

PV =nRT
Where,
P : Pressure in Pa
V : Volume
n : Number of moles
R : The gas constant
T : Temperature in kelvins

𝑛𝑅𝑇
𝑉= 𝑃
𝑀 𝑛𝑅𝑇
=
𝜌 𝑃

Where M is the mass of the feed

𝑀×𝑃
𝜌=
𝑛𝑅𝑇
𝑀
But,𝑀𝑟 = therefore
𝑛
𝑀𝑟×𝑃
𝜌= 𝑅𝑇

6.1.6 Ethanol vapour density

P = 101325 Pa
Mr = 46.06
R = 8314m3PaK-1kmol-1
T = 357 K
46.06×101325
𝜌𝑣𝑒 = 8314×357

𝜌𝑣𝑒 = 1.57 𝑘𝑔/𝑚3

6.1.7 Water vapour density

P = 101325 Pa
Mr = 18.01
R = 8314m3PaK-1kmol-1
 T = 357 K
18.01×101325
𝜌𝑣𝑤 = 8314×357

𝜌𝑣𝑤 = 0.61𝑘𝑔/𝑚3

Table 5: Liquid density

Component Density in kg/m3

Ethanol 789
Water 1000

Vapour density by section

Section density is given by:
𝜌 = ∑(𝜌𝑖 × 𝑀𝑓𝑖 )
Where,
ρ : vapour/liquid density in section
ρi : vapour/liquid density of component i
Mfi : mole fraction of component i

Vapour density in top section

𝑘𝑔 𝑘𝑔
𝜌𝑣𝑇 = (1.57 𝑚3 × 0.84) + (0.61 𝑚3 × 0.16)

𝜌𝑣𝑇 = 1.45𝑘𝑔/𝑚3
Vapour density in bottom section
Following the same procedure, vapour density in bottoms:
𝜌𝑣𝐵 = 0.71𝑘𝑔/𝑚3

Liquid density in top section

𝑘𝑔 𝑘𝑔
𝜌𝐿𝑇 = (789 𝑚3 × 0.84) + (1000 𝑚3 × 0.16)

𝜌𝐿𝑇 = 822.76 𝑘𝑔/𝑚3

Following the same procedure, liquid density in bottoms:
𝜌𝐿𝐵 = 976.79 𝑘𝑔/𝑚3
6.1.8 Flooding
The following equation is used to calculate the Liquid-Vapour flow (FLV) factor.
𝐿 𝜌 0.5
𝐹𝐿𝑉 = (𝑉) × ( 𝜌𝑉)
𝐿

Where,
FLV : Liquid-vapour flow factor
L : Liquid mass flow rate
V : Vapour mass flow rate
ρV : Vapour density
ρL : Liquid density
FLV will be calculated for both the enriching and the stripping section.
Enriching section (FLVTOP)
465 1.45 0.5
𝐹𝐿𝑉𝑇𝑂𝑃 = (779.19) × (822.76)

𝐹𝐿𝑉𝑇𝑂𝑃 =0.025

From the calculated FLV the corresponding CSB=K1TOP, value can be obtained

Figure 3: FLV chart (Sinnot R K, 2005a)

Assuming a tray spacing of 225 mm,

𝐾1𝑇𝑂𝑃 = 0.055
Bottom section ( FLVBOTTOM )
1719.03 0.71 0.5
𝐹𝐿𝑉𝐵𝑂𝑇𝑇𝑂𝑀 = ( 779.19 ) × (976.79)

𝐹𝐿𝑉𝐵𝑂𝑇𝑇𝑂𝑀 = 0.059
Also assuming a tray spacing of 225mm,
𝐾1𝐵𝑂𝑇𝑇𝑂𝑀 = 0.053

The flooding velocity is then calculated using the following equation

𝜌𝐿 −𝜌𝑉 0.5
𝑈𝐹 = 𝐾1 [ ]
𝜌𝑉

Where,
UF : Flooding vapour velocity
K1 : Constant
ρL : Liquid density
ρV : Vapour density

Enriching section flooding velocity

822.76−1.45 0.5
𝑈𝐹𝑇𝑂𝑃 = 0.055 [ ]
1.45

𝑈𝐹𝑇𝑂𝑃 = 1.31 𝑚/𝑠

Stripping section flooding velocity

976.79−0.71 0.5
𝑈𝐹𝐵𝑂𝑇𝑇𝑂𝑀 = 0.053 [ ]
0.71

𝑈𝐹𝐵𝑂𝑇𝑇𝑂𝑀 = 1.96 𝑚/𝑠

6.1.9 Maximum volumetric flow rate

Taking 80% flooding, the velocity at flooding is as follows:

Flow rate in the enriching section ( Uv,top )
= 0.8 × 1.31
Uv,top = 1.05 m/s

6.1.10 Flow rate in stripping section (Uv,bottom )

= 0.8×1.96
Uv,bottom = 1.57 m/s
6.1.11 Maximum volumetric flow rate ( Umax )
𝑉×𝑀𝑟
𝑈𝑚𝑎𝑥 = 𝜌×3600

Where,
Umax: Maximum volumetric flow rate
V : Molar vapour flowrate
ρ : Vapour density
Mr : Relative molecular mass

Maximum volumetric flow rate in the enriching section

18.75×42.08
𝑈𝑚𝑎𝑥,𝑡𝑜𝑝 = 1.45×3600

𝑈𝑚𝑎𝑥,𝑡𝑜𝑝 = 0.15 𝑚3 /𝑠

Maximum volumetric flow rate stripping section

18.75×18.01
𝑈𝑚𝑎𝑥,𝑏𝑜𝑡𝑡𝑜𝑚 = 0.71×3600

𝑈𝑚𝑎𝑥,𝑏𝑜𝑡𝑡𝑜𝑚 = 0.13 𝑚3 /𝑠

6.1.12 Calculation of column diameter

The following equation is used to calculate the column diameter of the distillation column.
4×𝐴 0.5
𝑑= ( )
𝜋

Where,
d : diameter
A : area

6.1.13 Enriching section diameter

0.15
𝐴𝑟𝑒𝑎 = = 0.14 𝑚2
1.05

So,
4×0.14 0.5
𝑑𝑡𝑜𝑝 = ( )
𝜋

Therefore 𝑑𝑡𝑜𝑝 = 0.42 𝑚

6.1.14 Stripping section diameter
0.13
𝐴𝑟𝑒𝑎 = = 0.08 𝑚2
1.57

So,
4×0.08 0.5
𝑑𝑏𝑜𝑡𝑡𝑜𝑚 = ( )
𝜋

𝑑𝑏𝑜𝑡𝑡𝑜𝑚 = 0.32 𝑚
Therefore the largest figure is taken as the column diameter, which is 0.42m.

6.1.15 Plate design

Provisional plate design

The area of the column ( Ac ) is calculated as follows:
𝜋𝑑𝑐2
𝐴𝑐 =
4
𝜋×0.422
𝐴𝑐 = 4

𝐴𝑐 = 0.14 𝑚2

The downcomer area (Ad ) is taken at 12% of the column area ( Ac ).

𝐴𝑑 = 0.12 × 0.14 = 0.017 𝑚2

Net area: 𝐴𝑛 = 𝐴𝑐 − 𝐴𝑑
𝐴𝑛 = 0.14 − 0.017
𝐴𝑛 = 0.123 𝑚2

Active area: 𝐴𝑎 = 𝐴𝑐 − 2𝐴𝑑

𝐴𝑎 = 0.14 − ( 2 × 0.017)
𝐴𝑎 = 0.106 𝑚2

The hole area (Ah) is taken as 10% of the active area (Aa).
𝐴ℎ = 0.1 × 0.106
𝐴ℎ = 0.0106 𝑚2

The weir length (lw) is calculated using the figure below which shows the relationship between
downcomer area and weir length.
Figure 4: Pitch (Sinnot R K, 2005b)

𝐴𝑑
From the y-axis: × 100
𝐴𝑐
0.017
× 100 = 12%
0.14
𝐿𝑤
The corresponding value can be obtained from the figure above. The value is determined to
𝐷𝑐

be 0.76
Weir length: 𝐿𝑤 = 0.76 × 0.42
𝐿𝑤 = 0.32 𝑚

6.1.16 Weir height

Let weir height (hw) be 40mm.

Weeping
The minimum design vapour velocity is given by
[ 𝐾2 −0.90(25.4−𝑑ℎ )]
[𝑈ℎ ]𝑚𝑖𝑛 = [𝜌𝑣 ]0.5

Where,
Uh : minimum vapour velocity
dh : hole diameter
K2 : Constant
Weeping check
In order to determine K2 the depth of liquid over the weir (how) must be calculated first. The
Francis weir formula is utilised.
𝑙 2⁄3
ℎ𝑜𝑤 = 750 [𝜌 𝑤𝐿 ]
𝑙 𝑤

Where,
how : weir crest
Lw : weir length
lw : liquid flow rate
ρl : liquid density

Maximum liquid rate

1719.03
𝐿′ = = 0.48 𝑘𝑔/𝑠
3600

The minimum liquid rate at 70% turndown:

= 0.7 × 0.48 = 0.34 𝑘𝑔/𝑠

0.48 2⁄3
ℎ𝑜𝑤,𝑚𝑎𝑥 = 750 [976.79×0.32]

ℎ𝑜𝑤,𝑚𝑎𝑥 = 9.98 𝑚𝑚 𝑜𝑓 𝑙𝑖𝑞𝑢𝑖𝑑

0.34 2⁄3
ℎ𝑜𝑤,𝑚𝑖𝑛 = 750 [976.79×0.32]

ℎ𝑜𝑤,𝑚𝑖𝑛 = 7.93 𝑚𝑚 𝑜𝑓 𝑙𝑖𝑞𝑢𝑖𝑑

At minimum rate:
ℎ𝑤 + ℎ𝑜𝑤,𝑚𝑖𝑛 = 40 + 7.93 = 47.93 𝑚𝑚

K2 value is now determined the Weep point correlation chart.

Figure 5: Weep point correlation chart. (Sinnot R K, 2005c)

The corresponding K2 value at 47.93mm is 30

Now, assuming a hole diameter of 5mm and since

[ 𝐾2 −0.90(25.4−𝑑ℎ )]
[𝑈ℎ ]𝑚𝑖𝑛 = [𝜌𝑣 ]0.5

Then,
30−0.90(25.4−5)]
[𝑈ℎ ]𝑚𝑖𝑛 = [1.45]0.5

[𝑈ℎ ]𝑚𝑖𝑛 = 9.67 𝑚/𝑠

Actual minimum vapour velocity

𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑣𝑎𝑝𝑜𝑢𝑟 𝑟𝑎𝑡𝑒
= ℎ𝑜𝑙𝑒 𝑎𝑟𝑒𝑎
0.8 ×0.13
= 0.0106

= 10.53 𝑚/𝑠
The minimum operating rate is well above the weeping point.
Plate pressure drop
Total pressure drop is the sum of the dry plate pressure drop (hd), the head of the clear liquid
the plate (hw + how) and residual losses.

Dry plate drop

𝑈 2𝜌
𝑉
ℎ𝑑 = 51 [ 𝐶ℎ ]
𝑜 𝜌𝐿

Where,
Uh : maximum vapour velocity through the holes
Co : orifice coefficient

𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒

𝑈ℎ = ℎ𝑜𝑙𝑒 𝑎𝑟𝑒𝑎
0.15
𝑈ℎ = = 14.15 𝑚/𝑠
0.0106

To determine Co:
𝑃𝑙𝑎𝑡𝑒 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 5
= =1
𝐻𝑜𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 5

Figure 6: Orifice coefficient (Sinnot R K, 2005d)

 𝐴 𝐴ℎ
Since𝐴ℎ ≈ = 10%, the corresponding Co value can be obtained 0.84.
𝑝 𝐴𝑎

Now dry plate drop:

14.45 2 1.45
ℎ𝑑 = 51 [ 0.84 ] × 976.79

ℎ𝑑 = 21.48 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑

Residual head, hr.

12.5 × 103
ℎ𝑟 = 𝜌𝐿

12.5 × 103
ℎ𝑟 = = 12.80 𝑚𝑚 𝑜𝑓 𝑙𝑖𝑞𝑢𝑖𝑑
976.79

Total drop, ht
ℎ𝑡 = ℎ𝑑 + (ℎ𝑤 + ℎ𝑜𝑤 ) + ℎ𝑟
ℎ𝑡 = 21.48 + (40 + 7.93) + 12.80
ℎ𝑡 = 82.21 𝑚𝑚 𝑜𝑓 𝑙𝑖𝑞𝑢𝑖𝑑

In pressure units total pressure drop:

∆𝑃𝑡 = 9.81 × 10−3 ℎ𝑡 𝜌𝐿
∆𝑃𝑡 = 9.81 × 10−3 × 82.21 × 976.79
∆𝑃𝑡 = 787.76𝑃𝑎

6.1.17 Downcomer design

The head loss in the downcomer may be estimated using the equation below.
𝐿 2
ℎ𝑑𝑐 = 166 [𝜌 𝑤𝑑 ]
𝐴 𝐿 𝑚

Where,
Lwd : liquid flow rate in downcomer
Am : the smallest value between downcomer area (Ad) and clearance area under
downcomer (Asp).

𝐴𝑠𝑝 = ℎ𝑠𝑝 𝐿𝑤
Assuming a value of 35mm for hsp, this implies that
 𝐴𝑠𝑝 = 0.035 × 0.32 = 0.011 𝑚2
It can be seen that 𝐴𝑠𝑝 < 𝐴𝑑 therefore 𝐴𝑚 = 𝐴𝑠𝑝 = 0.011
So,
0.48 2
ℎ𝑑𝑐 = 166 [976.79×0.011]

ℎ𝑑𝑐 = 0.33 𝑚𝑚
The downcomer backup come now be calculated.

ℎ𝑏 = (ℎ𝑤 + ℎ𝑜𝑤 ) + ℎ𝑡 + ℎ𝑑𝑐

ℎ𝑏 = (40 + 7.93) + 82.21 + 0.33
ℎ𝑏 = 130.47 𝑚𝑚

Downcomer backup height should be less than 0.5 times the plate spacing and weir height.
1
ℎ𝑏 < [0.225 + 0.04] = 0.133 𝑚
2

0.130 𝑚 < 0.133 𝑚

This shows that the plate spacing of 225 is satisfactory.

6.1.18 Entrainment
The correlation developed by Fair is used to estimate entrainment. Assumed percentage
flooding is 80% and FLV = 0.059. The corresponding fractional entrainment (ψ) is obtained
from the figure below.
The corresponding fractional entrainment (ψ) is found to be 0.041 which is well below 0.1 for
safe operation.
Figure 7: Entrainment (Sinnot R K, 2005e)

6.1.19 Trial Layout

Perforated area

Figure 8: Perforated area (Sinnot R K, 2005f)

𝐿𝑤 0.32
From x-axis = = = 0.76
𝐷𝑐 0.42

From the y-axis the corresponding value determined is 99°.

The angle subtended = 180 − 99 = 81°
Mean length of unperforated edge strips
81
= (0.25 − 40 × 10−3 )𝜋 × 180 = 0.28 𝑚2

Area of unperforated edge strips

= 40 × 10−3 × 0.28 = 0.011 𝑚2

Mean length of calming zone

= 𝐿𝑤 + 𝑤𝑖𝑑𝑡ℎ 𝑜𝑓 𝑢𝑛𝑝𝑒𝑟𝑓𝑜𝑟𝑎𝑡𝑒𝑑 𝑠𝑡𝑟𝑖𝑝
= 0.32 + 40 × 10−3
= 0.008 𝑚

Area of calming zone = 2(0.008 × 40 × 10−3 )

= 0.0006 𝑚2

Total area for perforations (Ap)

= 𝐴𝑎 − 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑢𝑛𝑝𝑒𝑟𝑓𝑜𝑟𝑎𝑡𝑒𝑑 𝑒𝑑𝑔𝑒 𝑠𝑡𝑟𝑖𝑝𝑠 − 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑐𝑎𝑙𝑚𝑖𝑛𝑔 𝑧𝑜𝑛𝑒
𝐴𝑝 = 0.038 − 0.011 − 0.0006
𝐴𝑝 = 0.0264 𝑚2

Assuming an equilateral triangular pattern, the total hole area as fraction of the perforated area
is expressed in the following equation.
2
𝐴ℎ 𝑑
= 0.9 [ 𝑙 ℎ ]
𝐴𝑝 𝑝

𝐴ℎ 0.0038
= 0.0264 = 0.14
𝐴𝑝

𝑙𝑝
From the graph below 𝑑 can be determined
ℎ
Figure 9: Hole area and pitch (Sinnot R K, 2005g)

𝑙𝑝
= 2.6, this is acceptable as it is greater than 2.0
𝑑ℎ

6.1.20 Number of holes

Hole diameter = 5 mm
2
𝜋 × (5×10−3 )
Area of one hole = = 1.96 × 10−5 𝑚2
4

𝑡𝑜𝑡𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 ℎ𝑜𝑙𝑒

Number of holes = 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑜𝑛𝑒 ℎ𝑜𝑙𝑒
0.0038
= 1.96×10−5

= 193 ℎ𝑜𝑙𝑒𝑠

6.1.21 Actual plate efficiency

Van Winkle correlation is used to calculate plate efficiency. The equation is as follows:
𝐸𝑚𝑣 = 0.07𝐷𝑔0.14 𝑆𝑐 0.25 𝑅𝑒 0.08
Where,
𝜎𝐿
Dg : surface tension = 𝜇𝐿 ×𝑢𝑉
0.067
= 0.00034×1

= 197.06
 𝜇𝐿
Sc : liquid Schmidt number = 𝜌𝐿 ×𝐷𝐿𝐾
0.00034
= 976.79×128×10−7

= 0.027

ℎ𝑤 ×𝑢𝑣 ×𝜌𝑣
Re : Reynolds number = × 𝐹𝐴
𝜇𝐿

40×10−3 ×1.45×1
= 0.00034×0.076

= 2244.58
𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒
uv : superficial vapour velocity = 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑐𝑜𝑙𝑢𝑚𝑛
0.05
= = 1 𝑚/𝑠
0.05

𝑎𝑟𝑒𝑎 𝑜𝑓 ℎ𝑜𝑙𝑒𝑠 0.0038

FA : fractional area = = = 0.076
𝑎𝑟𝑒𝑎 𝑜𝑓 𝑐𝑜𝑙𝑢𝑚𝑛 0.05

μL : liquid viscosity = 0.00034 kg/ms

σL : liquid surface tension = 67.21 mNm
DLK : liquid diffusivity = 128×10-7 m2/s
hw : weir height = 40 mm
ρL : 976.79 kg/m3
ρV : 1.45 kg/m3

Therefore,
𝐸𝑚𝑣 = 0.07 × (127.06)0.14 (0.027)0.25 (2244.58)0.08
= 0.78

6.1.22 Actual number of plates

Actual number of plates required, taking into consideration the calculated efficiency:
6
= 0.78

= 7.7
≈ 8 𝑝𝑙𝑎𝑡𝑒𝑠
6.1.23 Height of column

Height of the column (Hc) is predicted by:

𝐻𝑐 = (𝑁 + 1) × 𝐻𝑠 + ∆𝐻 + 𝑝𝑙𝑎𝑡𝑒 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠
Where,
N : actual number of stages
Hs : tray spacing
∆H : distance of liquid hold up and vapour disengagement
𝐻𝑐 = (8 + 1) × 0.225 + 0.3 + 0.005
𝐻𝑐 = 2.33𝑚

6.2 Mechanical design of distillation column

Design assumptions
 Diameter of column is 0.42m
 Material of construction is stainless steel
 Column is operating at atmospheric pressure
 Column is designed 10% above normal operating pressure
 Shell will be insulated with 70 mm of mineral wool
 Corrosion allowance is 2 mm
 Dynamic wind pressure is 1280 N/m2

6.2.1 Shell thickness

Minimum shell thickness is given by:

𝑃𝑖 𝐷𝑖
𝑒 =
2𝑓−𝑃𝑖

Where,
e : cylindrical column minimum shell thickness
Pi : design pressure = 0.1114575 N/mm2
Di : column diameter
f : design stress = 150 N/mm2
 0.1114575×0.42×103
So, 𝑒 = 2(150)−0.1114575

= 0.156 𝑚𝑚

After adding corrosion allowance, total thickness is 2.156 mm.

6.2.2 Skirt design

The skirt support will be made of a cylindrical shell that is welded to the base of the distillation
column. A flange at the bottom of the skirt will transmit the load to the foundations.
Bending stresses
The following equation is used to determine the bending stresses in the skirt support.
4×𝑀𝑠
𝜎𝑏𝑠 = 𝜋×(𝐷𝑠 +𝑡𝑠 )𝑡𝑠 𝐷𝑠

Where,
𝜎𝑏𝑠 : bending stress in the skirt
Ms : maximum bending moment elevated at the bottom
Ds : column diameter including thickness and insulation
ts : shell thickness

Diameter of column including shell thickness (Ds)

= 042 + 2 × (70 + 2.2) × 10−3
= 0.56

The loading: 𝐹𝑤 = 1280 × 0.56

= 716.8 𝑁/𝑚

Since height of column is 2.33,

716.8
Bending moment = 2.332 + 2

= 1945.71 𝑁𝑚
Now,
4×1945.71 ×103
𝜎𝑏𝑠 = 𝜋×(0.56+2.2×10−3 )2.2×10−3 ×0.56

= 3.58 𝑁/𝑚𝑚2
6.2.3 Dead weight stress

𝑊
Dead weight stresses 𝜎𝑤𝑠 = 𝜋(𝐷 +𝑡
𝑠 𝑠 )𝑡𝑠

Where,
W : total weight of the vessel and contents

Total weight of column (W) = 𝑤1 + 𝑤2 + 𝑤3

Where,
𝑤1 : Weight of the shell
𝑤2 : Weight of the plates
𝑤3 : Weight of insulation

Weight of shell: (𝑤1) = 240 × 𝐶𝑣 × 𝐷𝑚 × (𝐻𝑣 + 0.8 × 𝐷𝑚 ) × 𝑡𝑠

Where,
𝐶𝑣 : Factor accounting for weight of nozzle = 1.15
𝐷𝑚 : Diameter of column including shell thickness

2.2
𝐷𝑚 = 0.42 + (1000)

= 0.422
Therefore,
(𝑤1) = 240 × 1.15 × 0.422 × (2.33 + 0.8 × 0.422) × 2.2
= 683.54 𝑁
= 0.684 𝑘𝑁

Weight of plates (𝑤2 )

𝜋
Plate area = × 0.42
4

= 0.33 𝑚2
Weight of one plate = 1.2 × 0.33
= 0.40 𝑘𝑁
Since there are 8 plates, total weight of plates:
= 8 × 0.40
(𝑤2 ) = 3.20 𝑘𝑁
Weight of insulation (𝑤3 )
Insulation volume = 𝜋 × 𝐷𝑐 × 𝐻𝑣 × 𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠
= 𝜋 × 0.42 × 2.33 × 0.070
= 0.22 𝑚2

Weight of insulation = 0.22 × 130 × 9.81

= 280.57 𝑁

The value of weight of insulation has to be doubled to allow for fittings, therefore weight of
insulation is 561.14 N
This implies that total weight of the column:
𝑤1 + 𝑤2 + 𝑤3 = 0.68 + 3.20 + 0.28
= 4.16 𝑘𝑁
Dead weight stresses can now be calculated
4160
𝜎𝑤𝑠 = 𝜋(422+2.2)2.2