KM 451

CHEMICAL ENGINEERING DESING 1

DESIGN OF SEPERATION
UNITS
TEAM 3
091145088 HAZAL VARLI
131145030 LATİFE DEMİRBAŞ
131140058 CANSU İREM İZGİ
141140057 GÖZDE IŞIK Prof. Dr. Suna BALCI
131145075 ONUR POLAT Dr. Emine Kaya EKİNCİ
141140099 SİBEL YOGUN
Distillation Column Design

o Introduction to Design Project

o Method of Calculations

o Results of Our Design

 The Aim of Our Project
 In this project to design the
separation units including the
reboilers and condensers for
cumene production.We designed
the distillation columns for
separation of propylene, propane,
benzene, cumene, p-diisopropyl,
benzene multicomponent mixture.
This mixture is desired to be
distilled to 100 000 metric tons/yr
of cumene with a purity of 99.9%.
 Process Flowsheet

 PROCESSİN FOTOSU
WHAT IS DISTILLATION?

A process in which a liquid or vapor mixture

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

Distillation process based on :

 Relative volatility of components in a mixture

 Mixture’s compounding at its initial condition
1st Column  Flash Distillation Column

𝑲𝒎𝒐𝒍
V=7.704 𝒎𝒊𝒏
𝑲𝒎𝒐𝒍 ypropylene=0.616
F2=300 𝒎𝒊𝒏
ypropane =0.384
Xpropylene=0.003
Xpropane =0.016
XBenzene =0.353
XCumene =0.313 F3=L
XDIPB =0.313
Xpropylene=1.85*𝟏𝟎−𝟒
XBenzene =0.363
XCumene =0.321
XDIPB =0.321
Degrees of Freedom Analysis 1nd Column
+ 9 unknowns (V,L,F,Xi,Yi,SD,f,Tfeed,Pfeed)
-F = 300 kmol / min
-F= V+L
-F*Xf = V*Yi+L*Xi
-Ʃ xi= 1.0 Ʃ yi= 1.0
-SD= 0.99
-Xi,Yi= f(SD)
-F= V / L
-f=f(Tfeed,Pfeed )
Pfeed = 1.5 atm

Dof= 0 we can solve √

 Results for Flash Distillation
Feed Distillate Buttom

Molar Flow rate 300kmol/min 7,704 kmol /min 292,2 kmol /min
Pressure 1,5 atm 1,4 atm 1,3 atm
Temperature 80⁰C 65⁰C 95⁰C
Phase Liquid Vapor liquid

Component Feed Distillate Buttom

Propylene 0,003 0,384 -
Propane 0,016 0,616 1,85*10*-4
Benzene 0,353 - 0,363
Cumen 0,313 - 0,321
DIPB 0,313 - 0,321
2nd Column  Distillation Column

D=22.09 Kmol/min
XBenzene =0.87
XCumene =0.09
F2=292.2 kmol/min
XDIPB =0.04
XBenzene =0.067
XCumene =0.91
XDIPB =0.026

B=270.11 Kmol/min
XBenzene =1.33𝒙𝟏𝟎−𝟑
XCumene =0.97
XDIPB =0.021
 Degrees of Freedom Analysis 2nd Column
17 unknowns ( F, B, D, XF, XB, XD, Po, PT, Ki, α, Nmin, q, Q, Rmin, R, Ntheoritical, Eo, Nact)

 1)F = 292.2 kmol/min

 2)F=D+B
 3)SD=0.99
 4)FXF=DXD+BXB
 5)XB,XD=f(SD)
 6)XF=0.353
 7)PT=1.5 atm
 8)Pio / Pi = Ki
 9)α = Ki / Kj
 10)Nmin= ln[(XLK/MK)D *(XLK/MK)B] / lnα(XLK/MK)av
 11) q = 1-f= 0.95
 12) 1-q = ∑( αi xDİ / αi –Q)
 13) Rmin + 1 = ∑ (α xFİ / αi –Q)
 14) R/Rmin=1.5
 15) Ntheoritical= N-Nmin/ N+1 =0.75(1-(R-Rmin/R+1)0.566)
 16)Eo=0.44
 17)Nact= Ntheoritical / Eo
 Light and Heavy Key Components
Light key is a component which present in distillate
in large amounts while it present in bottom in small
amounts. Components which are lighter than the
light key doesn’t present in the bottom.
Heavy key is a component which present in bottom
in large amounts while it present in distillate in small
amounts. Components which are havier than the
heavy key doesn’t present in the distillate.

 Light key: Benzene

Heavy key: Cumene
 Dew Point And Bubble Point
Determination
Determination of vapor pressures by Antoine equation.

𝐁𝒊
LnPi= Aİ -
𝑪𝒊+𝑻(𝑲)

Bubble Point
∑yi=1
Dew Point
∑xi=1
Tdew= 100˚C
Tbubble=170 ˚C
The temperature where ∑xi=1 is dew point and it was
found 100 ˚C to trial-error solution.
The temperature where ∑yi=1 is bubble point and it
was found 170 ˚C to trial-error solution.
 Determination of Minimum
Number of Equilibrium Stages
The minimum number of stages was determined by using Fenske
equation.

𝐥𝐧 𝐱 𝐋𝐊Τ𝐇𝐊 𝐃
𝐱𝐋𝐊Τ𝐇𝐊 𝐁
𝐍𝐦𝐢𝐧 =
𝐥𝐧𝛂 𝐋𝐊Τ𝐇𝐊 𝐚𝐯

Nmin : Minimum number of trays

𝛼𝐿𝐾Τ𝐻𝐾 𝑎𝑣
: the average geometric relative
volatility of the light key to the heavy key
xLK: mol fraction of the light key
xHK: mol fraction of the heavy key
D: Distillate
B: Bottom product
 Determination of Minimum
Reflux Ratio
 The minimum reflux was determined by using Underwood equation.

n
αi xF,i
෍ =1−q
αi − θ
i=1

Rule: αHK < θ < αLK

it’s acceptable

n
αi xD,i
R min + 1 = ෍
αi − θ
i=1
 Determination of Reflux Ratio
 In most cases, ratio of actual reflux to minimum reflux is
selected at least 1.5 or above.
𝐑
= Ratio
𝐑 𝐦𝐢𝐧

Determination of Number of Ideal Equilibrium

Stages
Number of theoretical equilibrium stages was determined by
using Gilliland equation.

𝑹𝑫 − 𝑹𝑫,𝒎𝒊𝒏 𝒀 + 𝑵𝒎𝒊𝒏
𝑿= 𝑵𝒊𝒅𝒆𝒂𝒍 =
𝑹𝑫 + 𝟏 𝟏−𝒀
 Determination of Overall
Tray Efficiency
 Analytical expression developed by O’Connell correlation was used
for the determination of overall tray efficiency.

𝐄𝟎 = 𝟓𝟏 − 𝟑𝟐. 𝟓 𝐥𝐨𝐠 𝛍𝐋 𝛂𝐋𝐊/𝐇𝐊

𝐚𝐯
𝐄𝟎 = %𝟒𝟒

E0 : overall tray efficiency

αLK/HK : average relative volatility between the light and heavy keys
av
μL : liquid viscosity of the feed mixture (mPa.s)
 Determination of Actual
Number of Stages
𝐍𝐭𝐡𝐞𝐨𝐫𝐞𝐭𝐢𝐜𝐚𝐥
𝐍𝐚𝐜𝐭𝐮𝐚𝐥 =
𝐄𝟎

Nact : actual number of stages

Ntheoretical : theoretical number of stages
E0 : overall tray efficiency
 Determination of Position of Enriching and
Stripped Section

ND B xHK xHK
2 𝑵𝑫
log = 0.206 log
B = √
NB D xLK xHK 𝑵𝑩
D

𝑵𝑫 = 𝟖 𝒕𝒓𝒂𝒚𝒔

𝐍𝐚𝐜𝐭𝐮𝐚𝐥 = 𝑵𝑫 + 𝑵𝑩
𝑵𝑩 = 𝟏𝟕 𝒕𝒓𝒂𝒚𝒔

Feed Tray = 25
 Determination of Net Vapor
Velocity at Flooding Conditions

𝟎.𝟓
𝛔 𝟎.𝟐 𝛒𝐋 − 𝛒 𝐯 𝐦
𝐕𝐧𝐟 = 𝐂𝐬𝐛 ∗ ∗ 𝐕𝐧𝐟 = 𝟎, 𝟕𝟖𝟒
𝟐𝟎 𝛒𝐯 𝐬

Vnf : net vapor velocity at flooding conditions

Csb : Souders and Brown factor at flood
conditions in m/s
𝞼: surface tension in Dyne/cm
ρL , ρv : densities of liquid and vapor kg/m3
 Determination of Actual Vapor Velocity
The actual vapor velocity Vn is selected by assuming that it is 50 to
90 percent of the net vapor velocity at flood conditions (The lower
and upper values are only selected when some unusual flow
conditions are expected in the separation process.). Thus it is
selected that the actual vapor velocity is 60 percent net vapor
velocity at flood conditions.

𝐦
𝐕𝐧 = 𝟎. 𝟔 ∗ 𝐕𝐧𝐟 𝐕𝐧 = 𝟎. 𝟒𝟕𝟎
𝐬
 Determination of Net Column
Area

𝐦′ሶ 𝐯
𝐀𝐧 = 𝐀 𝐧 = 𝟏. 𝟔𝟖 𝐦𝟐
𝐕𝐧

𝑨𝒏 : net column area, 𝒎𝟐

𝒎′ሶ 𝒗 : volumetric flow rate of the vapor, m3/s
𝑽𝒏 : actual vapor velocity, m/s
 Determination of Cross
Sectional Area of Column
By assuming the downcomer area occupies 15 percent
of the cross-sectional area of the column, cross
sectional area of column determined. downcomer
net column
area
𝐀𝐧
𝐀𝐜 = 𝐀𝐧 + 𝐀𝐝 𝐀𝐜 = = 𝟏, 𝟗𝟕𝟔 𝐦𝟐
𝟎. 𝟖𝟓

𝑨𝒏 : net column area used in the separation process liquid

𝑨𝒅 : downcomer area
𝑨𝒄 : cross sectional area of the column vapor

Figure: Net column area and downcomer area

Diameter Determination of Column

𝝅𝑫𝟐 𝐃 = 𝟏, 𝟓𝟖 𝐦
𝐀𝐜 =
𝟒 r = 0,79

D: diameter of column, m
𝐀𝐜 : cross-sectional area of column, 𝐦𝟐
 Height Evaluation of Column

HC=(NACT-1)HS+∆H
HS= 0,46 𝐦 HC = 13,04 𝐦

HC : actual column height, m

Nact : actual number of trays
HS: plate spacing, m
∆H: additional height required for column operation.
 Condenser Design Calculation

Process fluid
Th,i=100˚C Th,o=100˚C

 Heat transfer area= 2.5 𝐦𝟐

Tc,o= 40˚C
 Heat duty= 22.2 𝐤𝐖
 mutility=19.3 kg/s
Tc,i= 25˚C
Pump Design Calculation
Equipment No P-103

Pump Type Centrifugal

Material of Stainless Steel

Constraction
Pump Power 753 w

Capacity 120kg/min

Pipeline No 3

Pipe Size 1.049 ( sch. 40 pipe)

Pipe Lenght 100 m

Fittings 2 globe,5 gate, 1

check valve,3 90˚
elbows
 Reboiler Design Calculation
Medium pressure
steam
Th,i=180˚C Th,o=180˚C

 Heat transfer area= 4 𝐦𝟐

 Heat duty= 21387 𝐤𝐖 Tc,o=162˚C
Tc,i=162˚C
 Mutility = 11 kg/s
Process fluid
 Results for 2nd Column
Feed Distillate Bottom

Molar flow rate 292,2kmol/min 22,09 kmol /min 270,11 kmol /min

Pressure 1,5 atm 1,4 atm 1,3 atm

Temperature 110⁰C 100⁰C 170 ⁰C

Phase Liquid vapor liquid

Component Feed Distillate Bottom

Propylene - - -

Propane - - -

Benzene 0,067 0,87 1,33*10-3

Cumene 0,91 0,09 0,97

DIPB 0,026 0,04 0,021

Theoretical Number of Stages 11

Actual Number of Stages 25

Column Efficiency (%) 0,44

Feed Plate Location NB=17 ND =8

Tray Spacing (m) 0,61

Column Diameter (m) 1,58

Column Height (m) 13,04m

 3th Column  Distillation Column

D=0.99 Kmol/min
XDCumene =0.99

F=267.16 Kmol/min
XCumene =0.95
XDIPB =0.005

B =0.01 Kmol/min
XBCumene =0.005
Tdew= 155˚C
Tbubble=163 ˚C

Light Key = Cumene

Heavy Key = DIPB
 1

0.9

0.8

0.7

0.6
x=y line
Eq. Curve
0.5
Feed Line
RS Op. Line
0.4 SS Op. Line

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
 Condenser Design Calculation

Th,i=158 ˚C Th,o=158˚C

 Heat transfer area= 3.5 𝐦𝟐

 Heat duty= 2.24 𝐤𝐖
 mutility=7.14 kg/s Tc,o= 100˚C

Tc,i= 25˚C
Pump Design Calculation
Equipment No P-102

Pump Type Centrifugal

Material of Stainless steel
Construction
Pump Power 3.04 kW
Capacity 0.14 3
m

Pipeline No 5
Pipe Size 0.1 m
Pipe Lenght 2m

Fitting 2 globe, 5 gate , 1 check

valve , 3 90˚ elbows
 Reboiler Design Calculation

Th,i=170 ˚C Th,o=160˚C

 Heat transfer
area=2.25𝐦𝟐
 Heat duty= 4.34 𝐤𝐖 Tc,o= 163˚C
Tc,i= 160˚C
 U = 900 W/𝐦𝟐 ˚C
 Feed Distillate Bottom

Molar flow rate 267,2 192,32 5,48

Pressure 1,1 1 1

Temperature 163 158 163

Phase Liquid vapor liquid

Component Feed Distillate Bottom

Propylene - - -
Propane - - -
Benzene - - -
Cumene 0,95 0,99 0,05
DIPB 0,05 0,01 0,95
Theoretical Number of Stages 9

Actual Number of Stages 11

Column Efficiency (%) 0,75

Feed Plate Location NB = 3 ND=8

Tray Spacing (m) 0,6

Column Diameter (m) 2,9

Column Height (m) 6,11

 Material of Construction

Trays Stainless steel

Column Stainless steel

Condenser Heat Duty (kW) 2,24 kW

Reboiler Heat Duty ( kW) 34 kW

Pump (W) 3,04 kW

 Purchased Cost of Equipment
Cost of Flash Distillation Column Cost of Continious Distillation Column

 D= 4 m D= 1.58 m
 H= 19.1 m H=13,04 m

Material adj. factor = 3.0 ( for stainless stell )

 Material adj. factor = 3.0 ( for Pressure adj. factor =4.6 ( for stainless stell )
stainless stell )
 Pressure adj. factor =4.6 ( for
stainless stell )
406400$
387580$
 Cost of Pump
Cost Of Condenser
A= 0.0025 m2 Pump power =753 W
Capacity = 2.07x𝟏𝟎−𝟑 m2 / s
Purchased cost of condenser is 10100 $

𝟓𝟓𝟖.𝟗 (Cp)2002 (2000$)x(2.4) = 4800$

(C )
c 2016 =( )x(10100) = 15816$
𝟑𝟓𝟔.𝟗

𝟗𝟕𝟎.𝟏
(Cp)2016 =(𝟔𝟗𝟗.𝟐)x(4800) = 6660$

Cost of Reboiler
Q= 21387 kW A = 4m2
Purchased cost of condenser is 1300 $

𝟓𝟓𝟖.𝟗
(Cc)2016 =( )x(1300) = 2035$
𝟑𝟓𝟔.𝟗
 Cost Of Cumene Column Cost of condenser

H= 6.67 A=3.5 m2
D= 2.9 m 𝟓𝟓𝟖.𝟗
(Cc)= 407.090$ (Cc)2016 =( )x(1000) = 1565.9$
𝟑𝟓𝟔.𝟗

Cost of Reboiler Cost of Pump

Q = 2.24 kW Pump power = 3.04 kW

A= 2.25 m2
𝟗𝟕𝟎.𝟏
𝟓𝟓𝟖.𝟗 (Cp)2016 =(𝟔𝟗𝟗.𝟐)x(1200) = 1664$
(CR)2016 =(𝟑𝟓𝟔.𝟗)x(1300) = 2040$
THANKS FOR LISTENING…