Dr Saad Al-Shahrani ChE 334: Separation Processes

Limiting condition
D
L
R
D

McCabe Thiele Graphical
Equilibrium-Stage
If the reflux ratio ( ) is increased to very large value, the
operating lines become the 45
o
line. The infinite reflux ratio occurs
in real life when the column is operated under what are called (total
reflux) condition
a) Minimum number of plates:
Under these conditions, no feed is added to the column (F=0) and
no products are withdrawn (D=0, B=0), but the vapor is boil up and
condensed to the column. So the column is just circulating vapor
and liquid up and down. Most columns are started up under total
reflux conditions.
Dr Saad Al-Shahrani ChE 334: Separation Processes
Distillation of Binary Mixture
Since the liquid flow rate in the column is same as the vapor flow
rate, and 0 . 1
V
L
V
L
The operating line
n
D
n n
x
D L
Dx
x
D L
L
y

1
m
B
m m
x
B L
Bx
x
B L
L
y

1
,
The composition in the base of the column under total reflux = x
B
, and
the composition of the liquid in the reflux drum = x
D
In this case the number of ideal plates is minimum.
Dr Saad Al-Shahrani ChE 334: Separation Processes
Binary Multistage Distillation
The minimum number of ideal plates can be done by:
a) Graphically as shown in the figure
y
X
D

X
F
X
B

X
B

x
y
1

y
2
y
3
y
4
X
1

X
2

X
3

Operating lines
as total reflux
Composition of liquid
in reflux drum
Composition of liquid
in re-boiler
y
1
= x
D
y
2
= x
1
y
3
= x
2
y
4
= x
3
x
B
= x
B

Minimum number of
plates = 3+reboiler
Dr Saad Al-Shahrani ChE 334: Separation Processes
Binary Multistage Distillation
b) Analytically (using Fenske Equation)
This equation gives the number of plates required under total reflux at
constant .

It is applicable to multi-component system as well as binary system
(= constant, total reflux, ideal system).
It is very useful for getting quick estimates of the size of a column.
Derivation of Fenske Equation
Consider two component (A,B) forming ideal solution
product bottom in ration mole
product in top ratio mole
/
/
/
/

B A
B A
B B
A A
B
A
AB
x x
y y
x y
x y
K
K

(1)
Dr Saad Al-Shahrani ChE 334: Separation Processes
An ideal mixture follows Raoults law and = vapor product ratio
Binary Multistage Distillation
P
x P
P
P
x P P
A
sat
A A
A
sat
A A

A
y
P
x P
P
P
x P P
B
sat
B B
B
sat
B B

B
y
sat
B
sat
A
B B
sat
B
A A
sat
A
B B
A A
B
A
AB
P
P
Px x P
Px x P
x y
x y
K
K

/
/
/
/

sat
B
sat
A
P P /
does not change much over the range of temperature
encountered,
AB
constant

1
,
1
A
A
B
A
A
A
B
A
x
x
x
x
y
y
y
y

(2)
Dr Saad Al-Shahrani ChE 334: Separation Processes
Binary Multistage Distillation
Substitute (2) in (1)
1
1
1
1
1 1

n
n
AB
n
n
x
x
y
y

AB
A
A
A
A
A
A
AB
x
x
y
y
y
y

1 1
,
1
D L
Dx
x
D L
L
y
D
n n

1
For plate n+1
Since D = 0 (total reflux), L / V= 1.0 ,
Then y
n+1
= x
n
and

1
1
1 1

n
n
AB
n
n
x
x
x
x

zero
Dr Saad Al-Shahrani ChE 334: Separation Processes
Binary Multistage Distillation
At the top of the column, if a total
condenser is used y
1
= x
D
, n = 0
Substitute in (2)
1
1
1 1 x
x
x
x
AB
D
D

For plate (1)

x
D

y
1
water
Re-boiler
V
b
y
b
L
b,
x
b
steam

x
1

x
2

x
3

x
n

x
n-1

x
0

y
2

y
3

y
4

y
n-1

y
n

y
r
B
B
AB
n
n
x
x
x
x

1 1

For plate (n)
. . . .
. . . .
. . . .
n
n
AB
n
n
x
x
x
x

1 1
1
1

For re-boiler plate

Dr Saad Al-Shahrani ChE 334: Separation Processes
Binary Multistage Distillation
If all equations are multiplied together and all the intermediate terms
canceled,
B
B n
AB
D
D
x
x
x
x

1
) (
1

B
B N
AB
D
D
x
x
x
x

1
) (
1
1 min

AB
B B D D
x x x x
N
ln
)] 1 / /( ) 1 / ln[(
1 min


AB
B B A D B A
AB
B D
x x x x
N
ln
) / /( ) / ln(
ln
] ) ration mole /( ) ration mole ln[(
1 or min
)
1
/( )
1
( ) (
B
B
D
D n
AB
x
x
x
x


Dr Saad Al-Shahrani ChE 334: Separation Processes
McCabe Thiele Graphical
Equilibrium-Stage
Example:
Calculate the minimum number of trays required to achieved a
separate from 5 mole % bottoms to 90 moles % distillate in a binary
column with =2.5
solution
x
B
= 0.05 , x
D
= 0.9

61 . 4 1
9163 . 0
14 . 5
,
5 . 2 ln
)] 05 . 0 1 / 05 . 0 /( ) 9 . 0 1 / 9 . 0 ln[(
1
min min


N N
AB
B B D D
x x x x
N
ln
)] 1 / /( ) 1 / ln[(
1 min


Dr Saad Al-Shahrani ChE 334: Separation Processes
McCabe Thiele Graphical
Equilibrium-Stage
Example: in a mixture to be fed to a continuous distillation column, the mole
fraction of phenol is 0.35, of o-cresol 0.15, of m-cresol 0.3 and of xylenes
0.2. it is hoped to obtain a product with a mole fraction of phenol 0.952, of
o-cresol 0.0474, of m-cresol 0.0.0006. if
p-o
= 1.26,
m-o
=0.7, estimate how
many theoretical plates would be required at total reflux.
Solution:
A light component (o-cresol)
B heavy component (m-cresol)
Total balance 100=D + B
For phenol 100*0.35=D*0.952+B*x
B,p
= zero
D= 36.8 Kmol, B = 63.2 Kmol
For o cresol
100*0.15=0.0474*36.8+x
B,o
*63.2
x
B,o
=0.21

Dr Saad Al-Shahrani ChE 334: Separation Processes
McCabe Thiele Graphical
Equilibrium-Stage

o-m
= 1/0.7=1.43
43 . 1 ln
)] 474 . 0 / 21 . 0 /( ) 0006 . 0 / 0474 . 0 ln[(
1
min
N
5 . 13
min
N
component Feed top Bottms
phenol 0.35 0.952 0
p-o
= 1.26
o-cresol 0.15 0.0474 0.21 o
o-o
= 1.0
m-cresol 0.3 0.0006 0.474
m-o
=0.7
xylenes 0.2 0 0.316
For m cresol
100*0.3=0.0006*36.8+x
B,m
*63.2

x
B,m
=0.474

x
B,X
=0.316

Dr Saad Al-Shahrani ChE 334: Separation Processes
McCabe Thiele Graphical
Equilibrium-Stage
b) Minimum Reflux Ratio
The next figure shows how changing the reflux ratio affects the
operating lines: the lower the reflux ratio, the closer the operating
line moves toward the equilibrium curve, and the larger the number
of plates.
If the reflux ratio finally reduced to the point where either operating
line intersects or becomes tangent to the VLE curve, an infinite
number of plates will be required and the reflux ratio is minimum.
Dr Saad Al-Shahrani ChE 334: Separation Processes
To obtain the R
Dmin
McCabe Thiele Graphical
Equilibrium-Stage
1 1
1

D
D
n
D
D
n
R
x
x
R
R
y
x x
y x
R
R
D
D
D
D

1
min
min
x y
y x
R
D
D



min
or
1
intercept ab
min


D
D
R
x
y`
1
min

D
D
R
x
x
a
b
x`
(x
D
,x
D
)
y
x
D
x
D
Dr Saad Al-Shahrani ChE 334: Separation Processes
McCabe Thiele Graphical
Equilibrium-Stage
If the equilibrium curve
has a cavity upward, e.g.,
the curve for water-
ethanol shown in the
figure in this case the
minimum reflux ratio
must be computed from
the slope of the operating
line (ac) that is tangent to
the equilibrium
x y
y x
R
D
D

min
x`
1
min

D
D
R
x
a
b
y`
Feed line
Non-ideal
Line VLE
c
y`
Dr Saad Al-Shahrani ChE 334: Separation Processes
McCabe Thiele Graphical
Equilibrium-Stage
Examole. A continuous fractionating column is to be design to separate 30.W Ib/h of
a mixture of 40 percent benzene and 60 percent toluene into an overhead
product containing 97 percent benzene and a bottom product containing 98
percent toluene. These percentages are by weight. A reflux ratio of 3.5 mol to 1
mol of product is to be used. The molal latent heats of benzene and toluene are
7,360 and 7,960 cal/ gmol, respectively. Benzene and toluene form an id91
system with a relative volatility of about 2.5; the equilibrium curve is shown in
Fig. 18-16. The feed has a boiling point of 95
o
C at a pressure of 1 atm. (a)
Calculate the moles of overhead product and bottom product per hour. (b)
Determine the number of deal plate and the position of the feed plate (i) if the
feed is liquid and at its boiling point. ii)if the feed is liquid and at 20
o
C (specific
heat 0.44 cal/ g-
o
C) (iii) if the feed is a mixture of two-thirds and one-third liquid.
(c) If steam at 20 Ib,/in
2
(1.36 atm) gauge is used for heating, how much steam is
required per hour for each of the above three cases, neglecting heat losses and
assuming the reflux is a saturated liquid? (d) If cooling water enters the
condenser at 25C and leaves at 40C, how much cooling water a required, in
gallons per minute?
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
x
y
.
Feed line
2
1
3
4
5
6
7
8
9
10
R
x
D
=0.974 x
B
=0.0235
1
D
D
R
x
x
F
=0.44