Distillation Column Design calculations

Experimental Data Refra

Component Refractive Index, n Mole Fraction of EtOH 1.355
Feed 1.3508 0.15
Pure ethanol 1.3559 1 1.35
f(x) = 0
Distilled water 1.3324 0 R² = 1
1.345

Reflux Ratio, R 1.6 2.6 3.2

Refraction index
1.34
Kettle Temperature, TI1 (°C) 84.3 84.5 84.6
1.335
Kettle Power Set (%) 30 30 30
1.3324
Column Bottom 1.33
Temperature, TI2 (°C) 82.3 82 82.3

1.325
Intermediate Stage Column
78.8 79.1 78.7
Temperature, TI3 (°C)
1.32
0 0.0
Column Top Temperature,
76.1 76.2 76.1
TI4 (°C)
Column Head Temperature,
TIC5 (°C) 76.6 77 77

Preheating Temperature,
82 71 80.1
TIC6 (°C)
Condenser Cooling Water 28.5 28 27.9
Inlet Temperature, TI7 (°C)

Condenser Cooling Water

29.6 29.1 29
Outlet Temperature, TI8 (°C)

Dosing Pump, FI1 (%) 10 10 10

Cooling Water Flow Rate in 200 200 200
Condenser, Q (L/h)

Refractive Index, n
Reflux Ratio, R
Bottom Distillate
1.6 1.3496 1.3571
2.6 1.3473 1.3568
3.2 1.3472 1.3567

Physical Data of Components

Component Ethanol Water
Molecular wt (kg/kgmol) 46.069 18.015
Boiling Point (°C) 78.3 100
Critical Temperature, Tc (K) 516.2 647.3
Hvap at BP (J/mol) 38770 40683
Mole Fraction of Components
Reflux Ratio 1.6 2.6 3.2
Mole Fraction of EtOH in
0.15 0.15 0.15
Feed
Mole Fraction of H2O in
0.85 0.85 0.85
Feed
Mole Fraction of EtOH in
0.201303993480032 0.198859005704971 0.19804400978
Distillate
Mole Fraction of H2O in
0.798696006519968 0.801140994295029 0.80195599022
Distillate
Mole Fraction of EtOH in
0.140179299103504 0.121434392828035 0.120619396903
Residue
Mole Fraction of H2O in
0.859820700896496 0.878565607171965 0.879380603097
Residue

We know,
Volumetric Flow Rate in
15
Feed (L/h)

Mass Balance Conversion factor

Overall F=B+D L m3
Component FxF = BxB + DxD 1000 1

Reflux Ratio, R 1.6 2.6 3.2

Mass Fraction of EtOH in
Feed, xF 0.31095346733804 0.31095346733804 0.310953467338

Mass Fraction of EtOH in

Distillate, xD 0.391924768363486 0.388290110312823 0.387073856785

Mass Fraction of EtOH in

Residue, xB 0.294242789919661 0.261153675988894 0.259678127201

Density of mixture in Feed,

T (°C) ρEtOH (kg/m3) ρH2O (kg/m3) ρmixture (kg/m3)
20 788.886 1002.09 935.7934769497

Mass flow rates,

Reflux Ratio, R 1.6 2.6 3.2
Feed flow rate, F (kg/h) 14.0369021542449 14.0369021542449 14.03690215424

Distillate flow rate, D (kg/h) 2.40132466182426 5.49830426019907 5.649694340475

Residue flow rate, B (kg/h) 11.6355774924207 8.53859789404584 8.387207813769

Calculated data from experimental data,
Reflux Ratio, R 1.6 2.6
Component Ethanol Water Ethanol Water
Hvap at 20°C (kJ/kg) [feed] 922.98725824307 2450.12489592007 922.9872582431 2450.124896

Hvap at TI2 (kJ/kg) [reboiler] 855.288805921552 2317.65195670275 844.4637391738 2302.192617

Hvap at TI4 (kJ/kg)

844.185895070438 2301.80405217874 854.85467451 2317.019151
[condenser]
Hvap, mixture in feed (kJ/kg) 1975.25615238198 1975.25615238198
Hvap, mixture in reboiler (kJ/kg) 1887.36214334118 1921.50136215514
Hvap, mixture in condenser (kJ/kg) 1730.52739359166 1749.27514494942

Conversion factors
hour seconds J kJ
1 3600 1000 1

Specific heat capacity of water at different temperature,

T (°C) CP,water (J/kg.°C) ρH2O (kg/m3)
28 4178.8
28.45 4178.71 996.759
28.55 4178.69 996.696
29.05 4178.59 996.377
29 4178.6

Total heating power at the

2000
kettle (W)

Condenser & Reboiler Duties,

Reflux Ratio, R 1.6 2.6 3.2
Total Cooling Power
Required at Condenser, Qc 3.00123641147352 9.61804698173574 11.45304830747
(kW)

Total Heating Power

Required at Reboiler, Qr 2.55391120112503 9.61804698173574 10.97316602542
(kW)

Cooling Power Released (W) 231.302831579444 231.38242268 231.398155605

Heating Power Released (W) 600 600 600

Operating Cost Analysis

Assuming distillation coulmn is operating 24 hours a day and 365 days a year. Note that Industrial Pricing & Tariff set by Saraw
The small-scale operation needs to be scaled up to produce 1 metric ton per hour (1000kg/h) of 0.8 mol% EtOH in H2O

Small Scale Operation Large Scale Operation

Reflux Ratio
Qc (kW) Qr (kW) Qc (kW) Qr (kW)

1.6 3.01 2.56 1249.83 1063.54

2.6 9.62 9.62 1749.28 1749.28
3.2 11.46 10.98 2027.20 1942.26

Design of Total Condenser and Partial Reboiler

From Pg 637 of Coulson Richardson

Overall heat transfer

Hot fluid Cold fluid
coefficient, U (W/m2.°C)

Condensers
Organic vapours Water 700-1000
Vaporisers/Reboilers
Steam Light organics 900-1200

Chosen condenser configuration: Horizontal with condensation in the shell and cooling medium in the tubes
Chosen reboiler: Kettle reboiler, high rates of vaporisation and horizontal reboilers are easier to maintain. (Pg 728)
Overall heat transfer
Heat Exchanger Type coefficient, U
(W/m2.°C)
Horizontal condenser with
800
coiled cooling tube
Kettle reboiler 1000

Theoretical value for mole fraction of EtOH

xF 0.15
xD 0.8
xB 0.1

Determination of saturated temperature of mixture

EtOH Water
Tsat at 1 atm (°C)
78.3 100
Distillate Residue
Tsat of mixture at 1 atm (°C)
82.64 97.83

Conversion factor
m2 ft2 kW W
 1 10.7639 1 1000

Reflux Ratio, R 1.6 2.6 3.2

∆Tm (°C) 53.5881183772025 54.08813577161 54.18813921
Condenser Acondenser (m2) 29.1535086896217 40.42649834374 46.76295161
2
Acondenser (ft ) 313.805452184219 435.1467855221 503.3517348
∆Tm (°C) 14.507029909547 14.54420725943 14.34929154
2
Reboiler Areboiler (m ) 73.312225828027 120.2729797332 135.3556967
Areboiler (ft2) 789.1254675903 1294.60632655 1456.955184

Purchase Cost Analysis Parameters

USD MYR
1 4.42
Marshall and Swift index (M 792
& S)
Correction Factor, Fc
Distillation Column 1.15
Condenser 1.00
Reboiler 1.45

Capital Cost Analysis

Reflux Ratio, R 1.6 2.6 3.2
Diameter of Column (ft) 3.04567870488252 3.04567870488252 3.045678704883 12,000,000.00
Height of Column (ft) 27.559056 17.716536 15.748032
Area of Condenser (ft2) 313.805452184219 435.146785522141 503.3517348367 10,000,000.00
2
Area of Reboiler (ft ) 789.1254675903 1294.60632655047 1456.955183679
Cost of Column (USD) 44,966.06 31,549.51 28,705.71 8,000,000.00
Cost of Condenser (USD) 39,555.04 48,919.92 53,776.06
Cost of Reboiler (USD) 81,882.89 112,963.39 121,979.89 Cost (RM) 6,000,000.00
Cost of Column (RM) 198,749.97 139,448.83 126,879.24
Cost of Condenser (RM) 174,833.27 216,226.05 237,690.20
4,000,000.00
Cost of Reboiler (RM) 361,922.35 499,298.19 539,151.10
Capital Cost of Plant (RM) 735,505.59 854,973.07 903,720.54
2,000,000.00

Total Cost Analysis

0.00
Reflux Ratio, R 1.6 2.6 3.2 1.5
Annual Operating Cost (RM) 5,268,926.94 7,968,298.14 9,040,833.48
Capital Cost (RM) 735,505.59 854,973.07 903,720.54
Total Cost (RM) 6,004,432.53 8,823,271.21 9,944,554.02 An

We found out that the optimum reflux ratio is 1.6. Thus, the following details are finalised design of distillation column.
Reflux Ratio, R 1.6
Cooling Duty, Qc (kW) 1249.83
Heating Duty, Qr (kW) 1063.54
Area of Condenser (m2) 29.15
2
Area of Reboiler (m ) 73.31
Diameter of Column (m) 0.9283
Height of Column (m) 8.4
Tray Spacing (m) 0.6
No. of Theoretical Trays 14
Column Performance (%) 70
 Refractive index against Mole Fraction of EtOH
1.355

1.35 1.3508
f(x) = 0.122666666666666 x + 1.3324
1.345
R² = 1
Refraction index

1.34

1.335
1.3324
1.33

1.325

1.32
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16

Mole Fraction of Ethanol

 3.2
Ethanol Water
922.9872582 2450.124896

855.2888059 2317.651957

844.1858951 2301.804052

1975.25615238198
1937.90823242047
1737.59817038706
 Pricing & Tariff set by Sarawak Energy is RM0.26/unit for 3000 units above.
8 mol% EtOH in H2O
Daily Energy Consumption Annualised Electricity Cost
Electricity Cost (RM/day)
(kWh) (RM) Annualised
Operating Cost
(RM)
Condenser Reboiler Condenser Reboiler Condenser Reboiler

29995.81 25525.02 7,798.91 6,636.51 2,846,602.19 2,422,324.75 5,268,926.94

41982.60 41982.60 10,915.48 10,915.48 3,984,149.07 3,984,149.07 7,968,298.14
48652.75 46614.20 12,649.71 12,119.69 4,617,145.86 4,423,687.63 9,040,833.48

aintain. (Pg 728)

m ft
 1 3.28084

Costings at Different Reflux Ratio

12,000,000.00

10,000,000.00

8,000,000.00
Cost (RM)

6,000,000.00

4,000,000.00

Optimum Reflux
2,000,000.00 Ratio, R = 1.6

0.00
1.5 1.7 1.9 2.1 2.3 2.5 2.7 2.9 3.1 3.3

Reflux Ratio, R

Annual Operating Cost (RM) Capital Cost (RM) Total Cost (RM)

of distillation column.
 Saturated Temperature of Ethanol,T1sat (°C) 78.2
Saturated Temperature of water,T 2
sat
(°C) 100
At P = 1 atm (kPa) 101.325

Constants for Antoine Equation A B C

Ethanol (1) 16.8958 3795.17 230.918
Water (2) 16.3872 3885.7 230.17

𝐴_12 𝐴_21
Margules Constant
1.6022 0.7947

ln⁡〖𝛾 _1=𝑥_2^2 [𝐴_12+ 〖 2(𝐴 〗 _21−𝐴_12 ) 𝑥_1 〗 ]

ln⁡〖𝛾 _2=𝑥_1^2 [𝐴_21+ 〖 2(𝐴 〗 _12−𝐴_21 ) 𝑥_2 〗 ]

0 0
1 1
1.00

0.90

0.80

0.70

0.60
Mole Fraction, y

0.50

0.40

0.30

0.20

0.10

0.00
0.0 0.1 0.2
Component Molar mass, M Tc (K) Zc
Ethanol 46.069 513.9 0.24
Water 18.015 647.1 0.229

Component T(graph) xd xb
Distillate 78 0.8
Bottom 92.5 0.05

𝜌=(𝑃𝑀𝑤 )/(𝑍_𝑐
𝑅𝑇)

T-xy Diagram
100.0

95.0

90.0
Temperature

86.5

85.0

80.0
77

75.0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

0.44Mole Fraction
 T (°C) 𝒙_𝟏 𝒙_𝟐 𝜸_𝟏 𝜸_𝟐

100.0 0.0 1.0 5.0 1.0

86.6 0.1 0.9 3.2 1.0
82.9 0.2 0.8 2.3 1.1
81.5 0.3 0.7 1.7 1.2
80.7 0.4 0.6 1.4 1.3
80.0 0.5 0.5 1.2 1.5
79.4 0.6 0.4 1.1 1.7
78.9 0.7 0.3 1.0 1.9
78.6 0.8 0.2 1.0 2.0
78.4 0.9 0.1 1.0 2.2
78.2 1.0 0.0 1.0 2.2

VLE Graph

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

Mole Fraction, x
 R
8.314
8.314

yd yb Density
0.8 29.9922835401208
0.25 0

6 0.7 0.8 0.9 1.0

P1sat (kPa) P2sat (kPa) 𝑷_𝑻 𝒚_𝟏

227.51 101.33 101.30 0.00

140.17 61.57 101.30 0.44
121.98 53.37 101.30 0.55
115.36 50.39 101.30 0.59
111.82 48.80 101.30 0.62
108.76 47.43 101.30 0.65
106.33 46.34 101.30 0.70
104.35 45.45 101.30 0.75
102.96 44.83 101.30 0.82
102.16 44.47 101.30 0.91
101.33 44.10 101.30 1.00
 1

0.9

0.8

0.7

0.6
Mole Fraction, y

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

Mole Fraction, x
 0.1 0
0.1 0.44

0.8 0
0.8 0.8

0.15 0
0.15 0.15

F 14000kg/hr
D 1000kg/hr
B 13000kg/hr

Xf 0.15
Xd 0.8
Xb 0.1

0.6 0.7 0.8 0.9 1

Total Reflux

0.9

0.8

0.7

0.6
Mole Fraction, y

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

Mole Fraction, x
 0.1 0.1
0.1 0.44

0.8 0.8
0 0.39

Rmin 1.1

min no. stages 6

Minimum reflux ratio:

𝑅_𝑚𝑖𝑛/(𝑅_𝑚𝑖𝑛−1)=𝑠𝑙𝑜𝑝𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑙𝑖𝑛𝑒=(0.8−0.39)/(0.8−0)

𝑅_𝑚𝑖𝑛=1.1

Minimum number of stages 6

0.6 0.7 0.8 0.9 1
Therefore, to reach the distillate composition we defined, we need to work with
defined, we need to work with reflux ratios higher than 1.1
R=1.6

0.9

0.8

0.7

0.6
Mole Fraction, y

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

Mole Fraction, x
 0.15 0.15
0.15 0.52

Rectifying line (Top operating line):

𝑥=𝑥_𝐷=0.8
0.8
0
𝑦=𝑥_𝐷/(𝑅+1)=0.31

𝑦=0.61𝑥+0.31

Stripping line (Bottom operating line):

𝑥=𝑥_𝐵=0.1 0.1
0.15

0.6 0.7 0.8 0.9 1 𝑦=6𝑥−0.5

q line: since feed is assumed to enter as saturated liquid, hence th

Theoretical number of trays 14

 0.8
0.31

0.1
0.4

r as saturated liquid, hence the slope is infinite and the q line is vertical line
R=2.6

0.9

0.8

0.7

0.6
Mole Fraction, y

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

Mole Fraction, x
 0.15 0.15
0.15 0.52

Rectifying line (Top operating line):

𝑥=𝑥_𝐷=0.8
0.8
0
𝑦=𝑥_𝐷/(𝑅+1)=0.22

𝑦=0.73𝑥+0.22

Stripping line (Bottom operating line):

𝑥=𝑥_𝐵=0.1 0.1
0.15

0.6 0.7 0.8 0.9 1 𝑦=4.6𝑥−0.36

q line: since feed is assumed to enter as saturated liquid, hence th

Theoretical number of trays 9

 0.8
0.22

0.1
0.33

r as saturated liquid, hence the slope is infinite and the q line is vertical line
R=3.2

0.9

0.8

0.7

0.6
Mole Fraction, y

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

Mole Fraction, x
 0.15 0.15
0.15 0.52

Rectifying line (Top operating line):

𝑥=𝑥_𝐷=0.8
0.8
0
𝑦=𝑥_𝐷/(𝑅+1)=0.19

𝑦=0.76𝑥+0.19

Stripping line (Bottom operating line):

𝑥=𝑥_𝐵=0.1 0.1
0.15

0.6 0.7 0.8 0.9 1 𝑦=4𝑥−0.3

q line: since feed is assumed to enter as saturated liquid, hence th

Theoretical number of trays 8

 0.8
0.19

0.1
0.3

r as saturated liquid, hence the slope is infinite and the q line is vertical line
 Graphical Temperature values from T-XY plot

Temperature (celsius) Temperature (K)

At the bottom 86.5 359.65
At the top 77 350.15

Component Ethanol Water

Molecular wt (kg/kgmol) 46.069 18.015

Components Temperature Density

359.65 718.2
Ethanol
350.15 729.02
359.65 957.344
water
350.15 964.166

F 14000kg/hr
D (vapor flow rate, Vw) 1000kg/hr 0.277777777777778
B (Liquid Flow Rate, Lw) 13000kg/hr 3.61111111111111

𝐹_𝐿𝑣=𝐿_𝑤/𝑉_𝑤 √(𝜌_𝑣/𝜌_𝐿 ) F_LV 0.515859838622932

𝑢_𝑓=𝐾_1 √((𝜌_𝐿−𝜌_𝑣)/𝜌_𝑣 ) From Chart, K_1 0.019
𝑢_𝑛=80% 𝑜𝑓 𝑢_𝑓
𝑀𝑎𝑥. 𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑉𝑎𝑝𝑜𝑟 𝑓𝑙𝑜𝑤 𝑅𝑎𝑡𝑒, u_f 0.478435107571855
𝑄_𝑚𝑎𝑥=(𝑉𝑎𝑝𝑜𝑟 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 u_n 0.382748086057484
𝑟𝑎𝑡𝑒)/(𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑣𝑎𝑝𝑜𝑟)
𝐴_𝑛𝑒𝑡=𝑄_𝑚𝑎𝑥/𝑢_𝑛 Q_max 0.227973124892233
Assume area of downcomer is 12% of total, A_net 0.595621854678573
𝐴_𝑐=𝐴_𝑛𝑒𝑡/(% 𝐶𝑜𝑙𝑢𝑚𝑛 𝑎𝑟𝑒𝑎)=𝜋/4 𝐷^2 0.676843016680196
A_c

Diameter, D 0.9283228395
 Average Density of Liquid Phase for Top and Bottom
Ethanol water
mole fraction at the bottom 0.44 0.56
mole fraction at the top 0.8 0.2
Mass at the bottom 20.27036 10.0884
Mass at the top 36.8552 3.603
Mass fraction at the bottom 0.6676939374335 0.33230606257
Mass fraction at the top 0.9109451236091 0.08905487639

Density at the bottom 797.66900102639

Density at the top 749.96089796383
Average Density Liquid Phase773.81494949511

kg/s
kg/s
Average Density of Vapor Phase for Top and Bottom
Ethanol water
mole fraction at the bottom 0.44 0.56
mole fraction at the top 0.8 0.2
Mass at the bottom 0.400815854387986 0.049870730778927
Mass at the top 0.728756098887247 0.017810975278188
Mass fraction at the bottom 0.889344985139823 0.110655014860177
Mass fraction at the top 0.97614283311637 0.02385716688363
Molecular Weight at bottom 30.35876
Molecular Weight at distillate (top) 40.4582
R constant 8.314
P (kPa) 101.325

Density at bottom 1.028751677728 Density at top

Average Density Vapor Phase 1.21846721147104
 𝜌_𝑣= 〖𝑃𝑀〗 _𝑤/𝑅𝑇
R = 8.314
(𝑘𝑃𝑎.𝑚^3)/(𝑘𝑔𝑚𝑜𝑙.𝐾)

1.408182745214
 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦, 𝜀=(𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑠𝑡𝑎
Assume tray spacing 0.6 m
Assume column efficiency 0.7

Reflux ratio 1.6 2.6 3.2

𝑇ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 ℎ𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑐𝑜𝑙𝑢𝑚
Number of theoretical trays 14 9 8
Efficiency 0.9333333 0.6 0.5333333
Number of actual trays 15 15 15 𝐴𝑐𝑡𝑢𝑎𝑙 ℎ𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑐𝑜𝑙𝑢𝑚𝑛=𝑇
Approx. no. of actual trays 20 13 12
Theoretical height of column (m) 8.4 5.4 4.8
Actual height of column (m) 12 7.8 7.2
=(𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑠𝑡𝑎𝑔𝑒𝑠)/(𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑎𝑐𝑡𝑢𝑎𝑙 𝑠𝑡𝑎𝑔𝑒𝑠)

𝑇ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 ℎ𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑐𝑜𝑙𝑢𝑚𝑛=𝑇𝑟𝑎𝑦 𝑠𝑝𝑎𝑐𝑖𝑛𝑔×𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑡𝑟𝑎𝑦𝑠

𝐴𝑐𝑡𝑢𝑎𝑙 ℎ𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑐𝑜𝑙𝑢𝑚𝑛=𝑇𝑟𝑎𝑦 𝑠𝑝𝑎𝑐𝑖𝑛𝑔×𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑎𝑐𝑡𝑢𝑎𝑙 𝑡𝑟𝑎𝑦𝑠