CHAPTER 4: DESIGN OF DISTILLATION TOWER

CHAPTER 4
DISGN F DISTILLATION TOWER

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4. Chapter 4: Design of Distillation Tower

4.1 Definition
Distillation may be defined as the separation of the components of a liquid feed mixture by a
process involving partial vaporization through the application of heat.

In general, the vapor evolved is recovered in liquid form by condensation. The more volatile
(lighter) components of the liquid mixture are obtained in the vapor discharge at a higher
concentration. The extent of the separation is governed by two important factors: the properties
of the components involved and by the physical arrangement of the unit used for distillation.

4.1.1 Types of distillation

4.1.2 Fractional distillation.

Fractional distillation is the separation of a mixture into its component parts, or fractions.
Chemical compounds are separated by heating them to a temperature at which one or more
fractions of the mixture will vaporize. It uses distillation to fractionate.

Fractional distillation is the most common form of separation technology used in petroleum
refineries, petrochemical and chemical plants, natural gas processing and cryogenic air
separation plants. In most cases, the distillation is operated at acontinuous steady state. New
feed is always being added to the distillation columnand products are always being removed.
Unless the process is disturbed due to changes in feed, heat, ambient temperature, or
condensing, the amount of feed being added, and the amount of product being removed are
normally equal. This is known as continuous, steady-state fractional distillation.
4.1.3 Industrial distillation
Industrial distillation is typically performed in large, vertical cylindrical
columns known as "distillation or fractionation towers" or "distillation
columns" with diameters ranging from about 0.65 to 6 meters (2 to 20
ft) and heights ranging from about 6 to 60 meters (20 to 197 ft) or more.
The distillation towers have liquid outlets at intervals up the column
which allow for the withdrawal
By increasing the temperature of the product inside the columns, the
different products are separated. The "lightest" products (those with the
lowest boiling point) exit from the top of the columns and the "heaviest"
products (those with the highest boiling point) exit from the bottom of
the column.
of different fractions or products having different boiling points or boiling ranges.

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4.1.4 Basic distillation equipment and operation

4.1.5 The main components of distillation tower
Distillation tower are made up of several components, each of which is used eitherto transfer heat
energy or enhance material transfer. A typical distillation containsseveral major components:

1. A vertical shell where the separation of liquid components is carried out.

2. Column internals such as trays/plates and/or packings which are used toenhance
component separations.
3. A reboiler to provide the necessary vaporization for the distillation process.
4. A condenser to cool and condense the vapour leaving the top of the column.
5. A reflux drum to hold the condensed vapour from the top of the column so thatliquid
(reflux) can be recycled back to the column.

The vertical shell houses the column internals and together with the condenser and reboiler,
constitute a distillation column. A schematic of a typical distillationunit with a single feed and
two product streams is shown below “Figure 4-1”.

Figure 4- 1: Typical distillation unit.

4.1 Basic operation and terminology

The liquid mixture that is to be processed is known as the feed and this is introduced usually
somewhere near the middle of the column to a tray known as the feed tray.
The feed tray divides the column into a top (enriching or rectification)
section anda bottom (stripping) sectio

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. The feed flows down the column where it is collected at the bottom in the reboiler.

Heat is supplied to the reboiler to generate vapour. The source of heat input can be any suitable
fluid, although in most chemical plants this is normally steam. Inrefineries, the heating source
may be the output streams of other columns. The vapour raised in the reboiler is re-introduced
into the unit at the bottom of the column. The liquid removed from the reboiler is known as the
bottom’s product orsimply, bottoms. “Figure 4-2”.

Figure 4- 2 : Reboiler & Tray (side-section)

Figure 4- 3: Reflux drum & Condenser (side-section).

The vapour moves up the column, and as it exits the top of the unit, it is cooled by a condenser.
The condensed liquid is stored in a holding vessel known asthe reflux drum. Some of this
liquid is recycled back to the top of the column andthis is called the reflux. The condensed liquid
that is removed from the system isknown as the distillate or top product. “Figure 4-3”.

Thus, there are internal flows of vapour and liquid within the column as wellas external
flows of feeds and product streams, into and out of the column.
4.1.1 Types of distillation tower trays

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A. Bubble cap trays

A bubble cap tray has riser or chimney fitted over each hole, and a cap that coversthe riser. The
cap is mounted so that there is a space between riser and cap to allow the passage of vapour.
Vapour rises through the chimney and is directed downward by the cap, finally discharging
through slots in the cap, and finally bubbling through the liquid on the tray. "Figure 4-4 " shown
the Bubble cap trays.

Figure 4- 4: Bubble cap trays

A. Sieve trays

Sieve trays are simply metal plates with holes in them. Vapour passes straight upward through
the liquid on the plate. The arrangement, number and size of theholes are design parameters.
"Figure 4-5 " shown the Sieve trays.

Figure 4- 5: Sieve trays.

A. Valve trays

In valve trays, perforations are covered by liftable caps. Vapour flows lifts the caps, thus self-
creating a flow area for the passage of vapour. The lifting cap directs the vapour to flow
horizontally into the liquid, thus providing better mixingthan is possible in sieve trays. "Figure
4-6 " shown the Valve trays.

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Figure 4- 6: Valve trays.

4.1.1 Distillation tower packings

There is a clear trend to improve separations by supplementing the use of trays byadditions of
packings. Packings are passive devices that are designed to increase the interfacial area for
vapour-liquid contact. The “Figure 4-7” shown three different types of packings.

Figure 4- 7: Different types of packings.

4.1.2 Packings versus Trays

A tray column that is facing throughput problems may be de-bottlenecked by replacing a section
of trays with packings. This is because:

1. Packings provide extra inter-facial area for liquid-vapour contact.

2. Efficiency of separation is increased for the same column height.
3. Packed columns are shorter than trayed columns.
Packed columns are called continuous-contact columns while trayed columns arecalled staged-
contact columns because of the manner in which vapour and liquidare contacted.

4.2 Column Reboiler

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A reboiler “Figure 4-8” is a heat exchanger that is used to generate the vapor supplied to the
bottom tray of a distillation column. The liquid from the bottom of the column is partially
vaporized in the exchanger, which is usually of the shell-and-tube type. The heating medium is
most often condensing steam, but commercial heat-transfer fluids and other process streams are
also used. Boiling takes place either in the tubes or in the shell, depending on the type of
reboiler. Exchangers that supply vapor for other unit operations are referred to as vaporizers
but are similar in most respects to reboilers.

figure 4- 8: kettle reboiler.

4.2.1 Factors affecting distillation column operation
The performance of a distillation column is determined by many factors, forexample:

1. Feed conditions
• State of feed.
• Composition of feed.
• Trace elements that can severely affect the VLE (vapour liquid equilibrium)of liquid
mixtures.
2. Internal liquid and fluid flow conditions.
3. State of trays (packings).
4. conditions.

4.2.2 Weather Feed Conditions

The state of the feed mixture and feed composition affects the operating lines andhence the
number of stages required for separation. It also affects the location of feed tray. During
operation, if the deviations from design specifications are excessive, then the column may no
longer be able handle the separation task. To overcome the problems associated with the feed,
some columns are designed to have multiple feed points when the feed is expected to containing
varyingamounts of components.

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4.2.3 reflux Conditions

As the reflux ratio is increased, the gradient of operating line for the rectificationsection moves
towards a maximum value of 1. Physically, what this means is thatmore and more liquid that is
rich in the more volatile components are being recycled back into the column. Separation then
becomes better and thus less traysare needed to achieve the same degree of separation. Minimum
trays are requiredunder total reflux conditions, i.e., there is no withdrawal of distillate.

On the other hand, as reflux is decreased, the operating line for the rectification section moves
towards the equilibrium line. The ‘pinch’ between operating and equilibrium lines becomes
more pronounced and more and more trays are required.

figure 4- 9: VLE Plot.

The limiting condition occurs at minimum reflux ration, when an infinite numberof trays will be
required to effect separation. Most columns are designed to operate between 1.2 to 1.5 times
the minimum reflux ratio because this is approximately the region of minimum operating costs
(more reflux means higherreboiler duty). “Figure 4-9” shows this.

4.3 Vapour flow conditions

4.3.1 Adverse vapour flow conditions can cause:

A. Foaming.
B. entrainment.
C. weeping/dumping.
D. flooding.

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1. Foaming
Foaming refers to the expansion of liquid due to passage of vapour or gas. Although it provides
high interfacial liquid-vapour contact, excessive foaming often leads to liquid buildup on trays.
In some cases, foaming may be so bad that the foam mixes with liquid on the tray above.
Whether foaming will occur depends primarily on physical properties of the liquid mixtures but
is sometimesdue to tray designs and condition. Whatever the cause, separation efficiency is
always reduced.
2. Entrainment
Entrainment refers to the liquid carried by vapour up to the tray above and is againcaused by high
vapour flow rates. It is detrimental because tray efficiency is reduced: lower volatile material is
carried to a plate holding liquid of higher volatility. It could also contaminate high purity
distillate. Excessive entrainment can lead to flooding.

3. Weeping/Dumping
This phenomenon is caused by low vapour flow. The pressure exerted by the vapour is
insufficient to hold up the liquid on the tray. Therefore, liquid starts to leak through perforations.
Excessive weeping will lead to dumping. That is the liquid on all trays will crash (dump)
through to the base of the column (via a domino effect) and the column will have to be re-started.
Weeping is indicated bya sharp pressure drop in the column and reduced separation efficiency.

4. Flooding
Flooding is brought about by excessive vapour flow, causing liquid to be entrainedin the vapour
up the column. The increased pressure from excessive vapour also backs up the liquid in the
downcomer, causing an increase in liquid holdup on theplate above. Depending on the degree
of flooding, the maximum capacity of thecolumn may be severely reduced. Flooding is detected
by sharp increases in column differential pressure and significant decrease in separation
efficiency.

5. Reboiler Temperature
As a reboiler slowly plugs on the tube side, the bottoms temperature goes down and this leads
to low vapor flow. Online monitoring of the heat transfer coefficientin control system can identify
this problem early on along with the monitoring ofbottoms temperature. A self-cleaning heat
exchanger when used in place of a reboiler can mitigate this problem

1. Reduction in Vacuum
A slight drop in vacuum causes the boiling point(s) to go up, leading to low vapourflow, loss of
production and off spec products.

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2. Wet Feed

If a column is typically fed a dry hydrocarbon feed but the feed becomescontaminated with
water then at some point, when the water/ hydrocarbon mixtureenters the tower, the water can
vaporize so rapidly that it causes an over pressureevent. This can and will damage trays. This
effects column efficiency and productquality.

4.8. Column Diameter

Most of the above factors that affect column operation is due to vapour flow conditions: either
excessive or too low. Vapour flow velocity is dependent on column diameter. Weeping
determines the minimum vapour flow required whileflooding determines the maximum vapour
flow allowed, hence column capacity.Thus, if the column diameter is not sized properly, the
column will not perform well. Not only will operational problems occur, but the desired
separation duties may also not be achieved.

4.3.1 State of Trays and Packings

Remember that the actual number of trays required for a particular separation dutyis determined
by the efficiency of the plate, and the packings if packings are used.Thus, any factors that cause
a decrease in tray efficiency will also change the performance of the column. Tray efficiencies
are affected by fouling, wear and tear and corrosion.
4.3.2 Weather Conditions
Most distillation columns are open to the atmosphere. Although many of the columns are
insulated, changing weather conditions can still affect column operation.

4.4 Explanation of Design Calculation/Procedure

4.4.1 Principles concepts (Definitions)
o Mixtures
It is a homogeneous solution that contains several components in different concentrations.

4.4.2Hydrocarbon mixtures can be classified :

• According to the components:

1. Two material in the mixture.
2. More than two.
• According to the boiling point of the mixture:

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3. Real mixture: It is the mixture that have an initial and final boiling point and the
vapor formed as a result of evaporation of the liquid mixture highly concentrated
with lighter components , the real mixture is separated by normal distillation,
like crude oil .
4. Isotropic mixture: a mixture that has a constant boiling pointand vapor formed
as a result of evaporation of the liquid mixture contains same boiling
concentrations of the components in the liquid.
I. Boiling point
It is temperature at which the vapour pressure of a liquid equal the pressure of theatmosphere
above the liquid boiling point is directly proportional with the pressure, when the pressure on a
liquid is increased, the Boiling point is increased.
II. Bubble point
Is the temperature at which the first bubble of vapour will formed when heatingthe liquid
and it is property for liquids.
III. Dew point
Is the temperature at which the first drop of liquid will formed when cooling thevapour and it
is property for vapours.
4.4.3 The principle of the distillation process
When heating a liquid mixture to its boiling point, the vapour will be liberated , containing the
light component( more volatile ) of the low boiling point and higher vapor pressure while the liquid
containing heavier component ( less volatile ) of boiling point and low vapor pressure, the “Figure
4-10” show a simple distillation of water.

figure 4- 10: Simple.distillation of water

When heating the impure water and reach to the boiling , the vapor is rises and enter the
condenser and contact with cold surface and then condensation to the liquid

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4.5 Classification of distillation systems

• Binary distillation: it is separating process of a mixture containing only two components,
such as separation of ethanol from water.
- The methods used: McCabe–Thiele Graphical Method.
• Multi component distillation: it is separating process of a mixture containing three or more
components such as the separation of crude oil.
- The methods used : Fenske–Underwood–Gilliland Method

Notes:
We will use the principle of (Binary distillation) in the unit of fractionation and extraction of
LPG in the Abu Qir gas plant.

4.5.1 Key Parameters

4.5.1.1 Separation Factor
The degree of separation or product purity has a direct impact on the size of the column and
the required utilities. Higher purity will require more trays, more reflux, larger diameter,
and/or a reduced product quantity. One quantitative measure of the difficulty of a separation
is the separation factor, SF, defined as:

4.5.2 Relative Volatility

The volatility of the components is usually expressed as relative volatility, α. This quantity is
computed as the ratio of the equilibrium K-values of two components at a given temperature
and pressure. For fractionation calculations the α of the key components is important.
Therefore:

Notes:
This is a measure of the ease of separation. The larger α is, the easier is the separation

4.8.1. The vapor-liquid equilibrium constant

The vapor-liquid equilibrium constant or distribution coefficient for component A is defined
as:

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Where YA= mole fraction of A in the vapor phase and XA= mole fraction of A in the liquid
phase.
For light hydrocarbon systems (methane to decane), the K values have been determined semi
empirically and can be evaluated from the equations given in Table 4-1. In general, K is a
function of temperature, pressure, and composition.

Equilibrium K values for Light Hydrocarbon System

Where P is in psia, T is in R:
Table 4- 1: Equilibrium K values for Light Hydrocarbon System

Compound A B C D Eq. Form

Methane 292860 8.2445 0.8951 59.8465 (1)
Ethylene 600076.9 7.90595 0.84677 42.94594 (1)
Ethane 687248.2 7.90694 0.866 49.02654 (1)
Propylene 923484.7 7.71725 0.87871 47.67624 (1)
Propane 970688.6 7.15059 0.76984 6.90224 (2)
i-Butane 1166846 7.72668 0.92213 0 (1)
n-Butane 1280557 7.94986 0.96455 0 (1)
i-Pentane 1481583 7.58071 0.93159 0 (1)
n-Pentane 1524891 7.33129 0.89143 0 (1)
n-Hexane 1778901 6.96783 0.84634 0 (1)
n-Heptane 2013803 6.52914 0.79543 0 (1)
n-Octane 7646.816 12.48457 0.73152 0 (3)
n-Nonane 2551040 5.69313 0.67818 0 (1)
n-Decane 9760.457 13.80354 0.7147 0 (3)

4.6 Design Consideration

4.6.1 Operating Pressure

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Before any design calculations can be made on a fractionation problem, a tower operating
pressure must be determined. One of the primary considerations for operating pressure is the
cooling medium available for the reflux condenser. The overhead product will be at bubble
point conditions for a liquid product or at dew point conditions for a vapor product. The
bubble point (or dew point) pressure is
fixed by a desired component separation and the temperature of the cooling medium.
The cooling media typically used are air, water, and refrigerant. Air cooling is normally the
least expensive cooling method.

4.6.2 Reflux Ratio and Number of Stages

The design of a fractionation column is a capital cost versus energy cost trade-off problem.
The primary parameters are the number of stages and the reflux ratio. Reflux ratio may be
defined in several ways. For most calculations, reflux ratio is defined as the ratio of the molar
rate of reflux liquid divided by the molar rate of net overhead product. The reboiler duty is a
direct function of the reflux ratio as the fractionating column must maintain an overall heat
and material balance for a given separation.

figure 4- 11: Relationship between reflux ratio and number of stages

A fractionation column can only produce a desired separation between the limits of minimum
reflux and minimum stages. “Figure 4-11”illustrates the relationship between reflux ratio and
number of stages for a given separation. At minimum reflux an infinite number of stages is
required. At total reflux a minimum number of stages is required.

4.6.3 Minimum stages

The minimum stages can be calculated for most multicomponent systems by the Fenske
equation.

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Sm in this equation includes a partial reboiler and a partial condenser if these items are used.
The αavg is the column average relative volatility of the key components in the separation.
Various averaging techniques have been proposed such as square root averaging of the α at
the top and bottom of the column:

Minimum reflux ratio

The Underwood method is the most widely used of the methods for calculating minimum
reflux ratio. Underwood assumed constant relative volatility and constant molal overflow in
the development of this method. The first step is to evaluate θ by trial and error:

Where: q = 1 for saturated liquid , q = 0 for vapour, once θ is determined,

theminimum reflux ratio is:

Number of Stages
The number of theoretical stages required for a given separation at a reflux ratio between
minimum and total reflux can be determined from empirical relationships. Erbar and Maddox
made an extensive investigation of tray-by-tray fractionator calculations and developed the
correlation in “Figure 4-12“. This correlation relates the ratio of minimum stages to
theoretical stages to the minimum reflux ratio, Rm, and the operating reflux ratio, R
(where R = Lo/D).
“Figure 4-12“ can be used to determine an operating reflux for a given number of stages by
entering the figure at the value of Sm/S, moving up to the line representing the value of
Rm/(Rm + 1) and reading a value of R/(R + 1). The optimum operating reflux ratio has been
found to be near the minimum reflux ratio.

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figure 4- 12: Erbar-Maddox correlation of stages vs. Reflux

4.6.4 Tray Efficiency

All column design work is performed using theoretical trays. An actual tray will not achieve
equilibrium due to limitations of vapor-liquid contact time. In an actual column, more trays
are required to obtain the desired separation. This determination is usually accomplished by
the use of an overall tray efficiency defined as:
𝑻𝒉𝒆𝒐𝒓𝒆𝒕𝒊𝒄𝒂𝒍 𝒕𝒓𝒂𝒚𝒔
𝜀=
𝑨𝒄𝒖𝒂𝒍 𝒕𝒓𝒂𝒚𝒔
4.6.5 Location of feed trays
For a given feed composition and enthalpy, there is an optimum feed-tray location that
permits making the specified separation with the least energy consumption. It is also the tray
that will permit maximum feed rate without causing the column to flood.
The magnitude of the energy savings to be realized by changing feed tray location can be
very significant in some systems (10-20 percent reduction in heat input), but in other columns
the effects can be small.
We can determine location of feed trays by using the empirical equation given by Kirkbride
(1944):

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Where:
Nr = number of stages above the feed. including any partial condenser.
Ns = number of stages below the feed, including the reboiler.
B = molar flow bottom product.
D = molar flow top product.
𝑋𝑓.𝐻𝐾 = concentration of the heavy key in the feed.
𝑋𝑓.𝐿𝐾 = consecration of the light key in the feed.
𝑋𝑑.𝐻𝐾 = concentration of the heavy key in the top product.
𝑋𝑏.𝐿𝐾 = concentration of Ae light key if in the bottom product.

4.6.6 Column Diameter

• Relative Molecular Mass (RMM)
The relative molecular mass/relative formula mass is defined as the sum of all the individual
atomic masses of all the atoms in the formula (Mwt). e.g., for ionic compounds e.g.,NaCl =
23 + 35.5 58.5) or molecular mass for covalent elements or compounds.

𝑅𝑀𝑀(𝑘𝑔/𝑘𝑚𝑜𝑙) = Σ 𝑀𝑊𝑡 𝑂𝑓 𝐸𝑎𝑐ℎ 𝐶𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 × 𝑀𝑜𝑙𝑒 𝐹𝑟𝑎𝑐𝑡𝑖𝑜𝑛

• Volumetric flow rate
Is the volume of fluid which passes per unit time.
• Tray Spacing
Tray spacing is the distance between two trays. Generally, tray spacing ranges from 8 to 36
inches (200 mm to 900 mm). Prime factor in setting tray spacing is the economic trade-off
between column height and column diameter. Most columns have 550 mm tray spacing.
• Maximum allowable vapour velocity
Are determined for both the rectifying and stripping sections of the column. They may be
different. If too low, weeping occurs – liquid flows through the holes in the sieve tray, for
example. If too high flooding will occur and liquid will back to the next plate.

Where:
𝑈𝑣 = Maximum allowable vapour velocity , 𝑇 = Tray Spacing
𝜌𝐿 = Density of mixture liquid , 𝜌𝑣 = Density of mixture vapour.

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• Standard diameter
To keep the column diameter (and cost) as small as possible, columns are designed to operate
at the maximum permissible vapor velocity.

Values of standard diameter per ft is : 2.5, 3, 3.5, 4, 5, 6, 6.5, 8, 9, 10, 12, 15,
20.

4.7 Design of De-butanizer Steps

figure 4- 13: De-butanizer tower from Aspen hysys.

4.7.1 Feed condition

Mole Fraction
0.2410
Xpropane Xa
0.2532 Feed condition
Xi-butane Xb
0.2728 Feed(kg mole/hr) 92.01
Xn-butane Xc
0.1104
Pressure(psia) 174
Xi-pentane Xd Temperature( R ) 625.8
0.1226
Xn-pentane Xe
total 1

4.7.2 Estimate product splits from martial balance.

Distillate Component
𝐗(𝐚+𝐛+𝐜)𝐅 ∗ 𝐌𝐅 = 𝐗(𝐚+𝐛+𝐜)𝐃 ∗ 𝐌𝐃 + 𝐗(𝐚+𝐛+𝐜)𝐁 ∗ 𝐌𝐁
𝐗(𝐚+𝐛+𝐜)𝐅 ∗ 𝐌𝐅 70.57167
𝐗(𝐚+𝐛+𝐜)𝐃 ∗ 𝐌𝐃 69.8659
𝐗(𝐚+𝐛+𝐜)𝐁 ∗ 𝐌𝐁 0.9201

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Bottom Component
𝐗(𝐝+𝐞)𝐅 ∗ 𝐌𝐅 = 𝐗(𝐝+𝐞)𝐃 ∗ 𝐌𝐃 + 𝐗(𝐝+𝐞)𝐁 ∗ 𝐌𝐁
𝐗(𝐝+𝐞)𝐅 ∗ 𝐌𝐅 21.43833
𝐗(𝐝+𝐞)𝐃 ∗ 𝐌𝐃 0.2143833
𝐗(𝐝+𝐞)𝐁 ∗ 𝐌𝐁 21.2239467

Component Feed Distiliate Bottom

XF XF*F YD YD*D XW XW*W
propane 0.241 22.174 0.314877 22.17441 0 0
iso butane 0.2532 23.2969 0.330817 23.29693 0 0
n butane 0.2728 25.1003 0.352861 24.84932 0.01162 0.25100
iso pentane 0.1104 10.1579 0.001442 0.101579 0.465834 10.05632
n pentane 0.1226 11.2804 0 0 0.52253 11.2804
Total 1 92.01 1 70.422245 1 21.5877

4.7.3 Equilibrium K value for feed and relative volatility

At 174 psi and 625.8oR.

Relative
Equilibrium K Value for Feed
volatility
Component α=ki/kc
A B C D ln K K

a propane 970688.6 7.151 0.77 6.902 0.7395 2.0950 5.755

b i-butane 1166846 7.727 0.92 0 0.0011 1.0011 2.750
c n-butane 1280557 7.95 0.965 0 -0.2983 0.7420 2.038
d i-pentane 1481583 7.581 0.932 0 -1.0104 0.3640 1
e n-pentane 1524891 7.331 0.891 0 -1.1594 0.3136 0.861

Where:

See “Table 4-9” : Equilibrium K values for Light Hydrocarbon System.

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4.7.4 Calculation of Dew point & Boiling point temp.

At a pressure of 174 psi and 625.8 oR and make iteration to reach:

∑[𝑋𝐷 × 𝐾𝑖] = 1.
top temperature
Component YD ln K Ki α=Ki/Kc YD/Ki YD/a

propane 0.314878 0.709819 2.033623 5.8384 0.154836 0.053932

iso butane 0.330818 -0.04641 0.95465 2.74074 0.346533 0.120704
n butane 0.352862 -0.33597 0.714645 2.051701 0.493758 0.171985
iso pentane 0.001442 -1.05464 0.348318 1 0.004141 0.001442
n pentane 0 -1.2088 0.298555 0.857131 0 0
Total 1 0.999268 0.348064
trial temperature 162.0246827 F
622.0246827 R

bottom temperature
Component XW ln K Ki α=Ki/Kc Ki*XW α*XW

propane 0 1.435101 4.200071 3.985747 0 0

iso butane 0 0.825438 2.282881 2.166388 0 0
n butane 0.011627 0.620842 1.860495 1.765556 0.021632 0.020528
iso pentane 0.465835 0.052377 1.053773 1 0.490884 0.465835
n pentane 0.522538 -0.06943 0.932927 0.885321 0.48749 0.462614
Total 1 1.000006 0.948977
trial temperature 277.7381731 F
737.7381731 R

Notes:
Iso-pentane is the constant in calculation for determine Bp & Dp

4.7.5 Minimum number of stage by two methods

First method to calculate minimum number of stage: “Analytically” by using (Fenske
Equation):

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 CHAPTER 4: DESIGN OF DISTILLATION TOWER

Light Key
Distillate 9.2742663

Bottom 1.8712262

Avg 4.16584331 Theoretical

Stages 7.696797
(XLK)d (XLK)d *MD 70.469875 Tray 6.696797

(XHK)d (XHK)d *MD 0.1017945

(XLK)b (XLK)d *MB 21.189064

(XHK)b (XHK)b *MB 0.2492659

Notes:
Not always . If we are using a partial condenser, then it is act as a tray. Similarly, if there is a
reboiler it will be also act as a tray. So altogether a partial condenser and reboiler are using then
number of stages will be equal to number of trays +2.
In case the condenser is total , completely condense all vapours reaching it then it cannot be act
as a stage. So, in this case only reboiler can be count as a stage . And total number of stages =
number of trays +1.

Second method to calculate minimum number of stage: “Graphical” by using (Hangs Tebeck’s
method):
→ Assumptions :
1) System is applied on equivalent binary system.
2) Solved by McCabe–Thiele Graphical Method Graphically.
→ Conditions :
1) Assume R = 1
In the case where all the reflux is collected as distillate the reflux ratio would be 0:1. If no
distillate is collected then a reflux ratio is not assigned. Instead, we call this "total reflux" or
equilibration.

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2) P = 12 bar
3) Molar flow = 92.01 kg mol/hr.
4) q = 1 (For saturated liquid).
→ Target recovery = 99% of LPG.
→ Procedure:
1) Estimate product splits from martial balance.
Component Feed Distiliate Bottom
XF XF*F xD XD*MD XB XB*MB
propane 0.241 22.174 0.314877 22.17441 0 0
iso butane 0.2532 23.2969 0.330817 23.29693 0 0
n butane 0.2728 25.1003 0.352861 24.84932 0.01162 0.25100
iso pentane 0.1104 10.1579 0.001442 0.101579 0.465834 10.05632
n pentane 0.1226 11.2804 0 0 0.52253 11.2804
Total 1 92.01 1 70.42224576 1 21.5877

Equilibrium K value for feed and relative volatility calculation at 174 psi and 625.8 oR.

Component K 𝖺=𝑲𝒊/ 𝑲𝒄

a propane 2.0909 5.75359

b i-butane 0.98709 2.71614

LK c n-butane 0.74134 2.03992

HK d i-pentane 0.36341 1
e n-pentane 0.31188 0.85819

• Rectifying section
α𝒊 di 𝒅𝒊 Vi = Li + di
Li=
𝜶𝒊−𝟏

C3 5.75446 22.1744 4.663882 26.83829

iC4 2.749934 23.269 13.31304 36.660997
∑ 17.97692 63.44826

• Stripping section

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α𝒊 di ∝ 𝒊∗𝒅𝒊 𝐋′𝐢 = 𝐕𝐢 + 𝐛𝐢
V′i=
∝𝒍𝒌−∝𝒊
nC5 0.8615 11.28047 8.259057 19.53948
∑ 8.259057 19.53948

3) L = R * D = 1*70.42225=40.42225
V = (R+1) * D = (1+1) * 70.42225 = 140.8445
V′ = V - (1-q) F = 140.8445 - (1-1) * 92.01 = 140.8445
L′= V′ + q F = 140.8445+ 1*92.01 = 232.8541

4) Le = L - Σ Li = 70.4225 -17.97692= 52.44508

Ve = V - Σ Vi = 140.8445 -63.44826 = 77.395721
Le′ = L’ - Σ Li′ = 232.854 – 19.53948 = 213.315
Ve′ = V′- Σ Vi′ = 140.8445 – 8.25905 = 132.584
5) Slope (top operating line) = Le / Ve = 0.7
Slope (bottom operating line) = Le′ / Ve′ = 1.6
(Χικ )B 0.01162
Bottom line = 𝑋𝑏= (𝑋 𝜄𝜅)𝐵+(𝑋 ℎ𝜅)𝐵 = 0.01162+0.46583 = 0.02436

(𝑋𝐿𝐾)𝑑 0.35286
Distillate line = 𝑋𝑑=(𝑋𝐿𝐾)𝑑 + (𝑋𝐻𝐾)𝑑 =0.00144+0.35286 = 0.99593

(𝑋𝐿𝐾)𝑓 0.2728
Feed line = 𝑋𝑓= (𝑋𝐿𝐾)𝑓 + (𝑋𝐻𝐾)𝑓 = 0.2728+0.1104 = 0.711899

∝𝐿𝐾 𝑋 2𝑋
Equilibrium curve = 𝑦= =y
1+(∝𝐿𝐾−1) 𝑋 1+𝑋

x 0 0.2 0.4 0.6 0.8 1

y 0 0.333 0.57143 0.75 0.889 1
Theoretical number of trays = 7

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figure 4- 14: Theoretical number of trays – graphically

Figure 4 - 14

• Minimum reflux ratio (underwood equation)

Where: q = 1 for saturated liquid , q = 0 for vapour, once θ is determined, the minimum
reflux ratio is:

 × 𝑿𝑭  × 𝑿𝑫
Component XF XD Ki  XW
−𝜃 −𝜃
propane 0.2410 0.5451 2.0909 5.7535 0 0.29238 0.66131
i-butane 0.2532 0.2595 0.9870 2.7161 0 0.40334 0.41338

n-butane 0.2728 0.1947 0.7413 2.0399 0.01162 0.54090 0.38604

7
i-pentane 0.1104 0.0006 0.3634 1 0.46583 9.94626 0.05405

n-pentane 0.1226 0.0001 0.3118 0.8581 0.52253 0.68810 0.000561

Total 1 1 0.9999995 9.3977 1.40612

Notes:
Iso-pentane is the constant.

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R = 1.5 Rm
If 5 parts of the reflux go back down the distillation column and 1 part is collected as distillate,
then the reflux ratio is 5:1. In the case where all the reflux is collected as distillate the reflux
ratio would be 0:1. If no distillate is collected then a reflux ratio is not assigned. Instead, we
call this "total reflux" or equilibration.

Theta 1.0110996

Rm+1 1.4061288

Rm 0.4061288

R=1.5*Rm 0.6091933 Sm
R/R+1 0.3785706 s 0.52
Actual Sm
s= 0.52 14.80153303
Rm/Rm+1 0.2888276
tray 13.80153303

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4.7.6 Determine tray efficiency

Theoretical trays 7
𝜀= = = 0.5
𝐴𝑐𝑢𝑎𝑙 𝑡𝑟𝑎𝑦𝑠 14

✓ Determine of the Location of feed trays (Kirkbride method)

log(NT/NS) 0.289607
Nr/NS 1.948082
Nr 9.7808
NS 5.020733
RECHECK 1.948082

The location of feed tray is 10 from top.

▪ Column Diameter

Component Feed Distillate Bottom

XF XF*MF XD XD*MD XB XB*MB
a propane 0.241 22.174 0.314877 22.17441 0 0
b iso-butane 0.2532 23.2969 0.330817 23.29693 0 0
c n-butane 0.2728 25.1003 0.352861 24.84932 0.01162 0.25100
d iso-pentane 0.1104 10.1579 0.001442 0.101579 0.465834 10.05632
e n-pentane 0.1226 11.2804 0 0 0.52253 11.2804
Total 1 92.01 1 70.422245 1 21.5877

Component Molecular weight Standard Density(kg/m3)

propane 44 493
iso-butane 58 563
n-butane 58 573
iso-pentane 72 616
n-pentane 72 626

4.7.7 Calculate Relative Molecular Mass (RMM)

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𝑅𝑀𝑀(𝑘𝑔/𝑘𝑚𝑜𝑙) = ∑ 𝑀𝑊𝑡 𝑂𝑓 𝐸𝑎𝑐ℎ 𝐶𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 × 𝑀𝑜𝑙𝑒 𝐹𝑟𝑎𝑐𝑡𝑖𝑜𝑛

Component feed top bottom
propane 10.604 13.85462 0
iso butane 14.6856 19.18743 0
n butane 15.8224 20.46598 0.67436
iso pentane 7.9488 0.103854 33.5400
n pentane 8.8272 0 37.6227
total 57.888 53.6119 71.8371
• Calculate Density

→ Density of liquid (ꝬL) = Standard Density × XB for each component

𝑷𝑳(𝒌𝒈/𝒎𝟑)
component
propane 0
iso butane 0
n butane 6.65826
iso pentane 286.9537
n pentane 327.103
total 620.725

Density of Vapour (PV) =  v = n R T , where: n = m / RMMtop , = m / V

location Temperature(k) Pressure(bar)

feed 347.34 12
top 338.26 11.47
bottom 419.1 11.87

pressure 1147000 pa
R 8314 J/kg.k
Top Temperature 311.48 k
RMMTop 53.6119 kg/kmol
Ꝭv 21.865 kg/m3
4.7.8 Volumetric flow rate

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component Mass flow rate (kg/hr)

feed distillate liquid
propane 977.8996 977.89961 0
iso butane 1354.027 1354.0271 0
n butane 1458.896 1444.307 14.58896
iso pentane 733.0754 7.330754 725.744
n pentane 931.9015 0 931.901
total 5455.801 3783.564 1672.23

∴𝑉𝑡𝑜𝑝= 173.042𝑚3/ℎ𝑟 ,∴𝑉𝑏𝑜𝑡𝑡𝑜𝑚= 2.6940383 𝑚3/ℎ𝑟

4.7.9 Maximum Allowable Vapour Velocity

∵ Most columns have 550 mm tray spacing.

∵ Maximum allowable vapour velocity

ρL − ρv 1
Uv = ((−0.171 ∗ T 2 ) + (0.27 ∗ T) − 0.047) × ( )2
ρv

620.715−21.865 1
Uv = ((−0.171 ∗ 0.552 ) + (0.27 ∗ 0.55) − 0.047)( )2
21.865

∴ 𝑈𝑣= 0.2604
• Column Diameter
4∗𝑀𝑣 4∗0.366
𝐷𝑐 = √( ) ∗ 10 = √(𝜋∗0.2604∗21.865) ∗ 10 =2.8 m =9.38 ft
𝜋∗𝑃𝑣∗𝑈𝑣

Standard diameter = 10 ft =3 m

107