KNC 1013 S em 1 2021/2022 Week 5 : Case Study sections ( Part 2 lecture)

Learning objective

Recap on the week 4

Part 1 ( Theoretical section)

• Gain understanding on fundamental concept of Bernouli analysis and continuity equation
• Complete the tutorial section for the theoretical part
Part 2 ( Case study section)

• Apply the theoretical concept ( Wk 1 till week 4) to analyzed the ASU process
flow diagram (PFD) : Distillation coloumn analysis ( cont )

Week 5 Learning Objective

Part 1 ( Theoretical section)
• Gain understanding on fundamental concept of control volume and mass conservation ( integral
form)
• Complete the tutorial section for the theoretical part
Part 2 ( Case study section)

• Apply the theoretical concept (mass conservation ) on distillation coloumn

analysis in order to optimize the ASU performance as a subunit

• Perform hydraulic analysis on fractional coloumn

Task 1 : Application of Control Volume ( Mass Conservation ) in ASU PFD

Fig 2 Process flow diagram ( PFD) in typical air separation unit (ASU) . Stream table is describing the process parameters changes is shown in
the next table . The image is retrieved from https://en.dearast.com/products/liquefaction-air-
separation/?gclid=CjwKCAjw5c6LBhBdEiwAP9ejGz7IU45ii057GV0m302rGikUBHQ257O2HQUicqW-
1luOO08HBob_zBoC34IQAvD_BwE#filterloc?5xyFrom=site-NT
Stream No Mass flow rate (kg/hr) T (°C) P (kPa) Ar (mole O2 (mole N2 H2O
%) %) (mole (mole %)
%)
1 360,000 25 101.3 1 21 78
2 360,000 143.9 268 1 21 78
3 360,000 30 258 1 21 78
4 360,000 154.2 669 1 21 78
5 360,000 30 659 1 21 78
6 244,800 30 659 1 21 78
7 115,200 30 659 1 21 78
8 115,200 109.7 1210 1 21 78
9 115,200 24.7 1200 1 21 78
10 115,200 -163.8 1190 1 21 78
11 115,200 -172.8 659 1 21 78
12 244,800 -164.1 649 1 21 78
13 244,800 -164.1 649 1 71 78
14 214,511 -171.9 649 1.39 34.77 63.84
15 214,511 -180.6 639 1.39 34.77 63.84
16 214,511 -192.5 106 1.39 34.77 63.84
17 145,489 -178.6 517 0.45 1.68 97.87
18 145,489 -185.7 507 0.45 1.68 97.87
19 145,489 -195.5 106 0.45 1.68 97.87
20 68,483 -182.7 106 0.DI 99.99
21 68,483 -182.6 480 0.DI 99.99
22 68,483 0.1 470 0.DI 99.99
23 291,517 -194.2 106 1.1 4.69 94.21
24 291,517 -175 103.5 I.I 4.69 94.21
25 291,517 27 101.3 1.1 4.69 94.21
26 1,296,000 20 101.3 100
27 1,296,000 20 330 100
28 1,296,000 21.73 320 100
29 1,296,000 29.5 310 100
30 1,296,000 36.6 300 100
Introduction to Distillation (Fractional) Column

Fig 3 Cross Sectional Area of Distillation Column (a) overview; (b) detail of liquid on three successive trays; (c) plan
of one tray.
• Fractional ( or distillation column is used to separate or fractionate a mixture, based on the different boiling
points or volatilities of the components in a feed stream mixture of light” (low boiling point) and “heavy”
(high boiling point) hydrocarbons. The most volatile components become concentrated toward the top of the
column, and the least volatile toward the bottom.
• The essential parts of the column are: 1.
1.A reboiler, typically steam-heated, that boils the liquid from the bottom of the column, part of which
is withdrawn as the bottoms product, rich in the heavy components. The rest of the liquid is vaporized
and returned to the column.
2. A series of trays on which the liquid mixture is boiling. Vapor somewhat enriched in the lighter
components rises to the tray above, and liquid somewhat enriched in the heavier components falls to
the tray below
3. A condenser, typically cooled by water, liquefies the vapor from the top tray. Part of the liquid is
returned to the top tray as reflux, and the rest is withdrawn as the overhead product, rich in the light
components.
• As seen from Fig. 3( b), boiling liquid is continuously spilling over a weir at one side of every tray, from there
flowing via a downcomer and through a constriction to the tray below.
• Vapor, boiling from the liquid on each tray, is simultaneously flowing upward through bubble caps (which act
as liquid seals, and only a few of which are shown in the diagram) into the boiling liquid on the tray
immediately above.
Task 2 :

Mass transfer in distillation coloum is further limited by the hydrodynamics ( i.e behaviour of the fluid
motion, that is affected by the velocity, pressure, forces ) of the column. The size and number of trays or
packing height, the geometry of the tray or packing, the column operating conditions, the gas and liquid
properties and flow rates all have an influence on the column hydrodynamics and, there­fore, the mass
transfer efficiency achieved . Knowledge of the influence of these parameters on column hydrodynamics will
aid in improving the accuracy of current mass transfer and hydrodynamic models used in separation column
design.

Separation efficiency is reduced when a fraction of the liquid on the tray is transported with the rising gas to
the tray above, as a results of higher vapor flow rate. This phenomenon is called entrainment . It is
detrimental in that the effective tray efficiency is lowered because liquid from a tray of lower volatility is
carried to a tray of higher volatility, thereby diluting the effect of distillation.
(less volatile liquid components from bottom tray are mixed with liquid having relatively more volatile
materials on the overhead tray) =ideal chemical potential changes required for heat transfer and mass
transfer are going to be reduced .

Column operation becomes unstable when the mass fraction of liquid droplets suspended in the rising gas
becomes too large, causing flooding to occur. Therefore, the key to improve the performance of ASU
column is to select appropriate column tray parameter in such that flooding, and entrainment could be
minimized . The maximum Liquid flow rate that can be accommodate in the coloumn must be determined
. If the liquid flow rate exceeding Liquid flow rate max, it will cause the flooding
Table 2 represents the tray column geometry dataset used in ASU

Key tray geometry parameter

Discharge coefficient performance , CD

Depth of the weir (mm) (d)

Height of the weir (mm) (D)

Width of the weir (m) (W)

Depth of the opening at bottom of the weir (mm)δ

1. Analyze the liquid phase velocity changes throughout the column
2. Analyze relation between discharge coefficient, tray width, and depth of the weir
3. Determine the total available head in the liquid phase
4. Analyze the relation the maximum liquid flow rate that is attainable in the column
with the column geometry