CHNG2806-9206

Separation Processes

Week 2: McCabe-Thiele
graphical method

Dr David Wang

Prepared by
Dr Amirali Ebrahimi Ghadi
School of Chemical and Biomolecular Engineering
Faculty of Engineering and IT

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 Textbook and Reference

– Separation Process Principles

– Chapter 7: Distillation of Binary Mixtures

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 Learning Outcomes

– To understand the principles governing the design of distillation

columns

– To apply graphic methods for the sizing of distillation columns

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 Previously...
– x-y diagram (McCabe-Thiele diagram)
– Operating lines

To find the operating line of stripping

section, we need to find L
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 Feed-stage consideration

– Feed plate consideration

– The impact of the thermal
condition of the feed
stream.
– The location of the feed Rectification section:
tray (ie where the feed
enters the column).

Stripping section:

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 Feed-stage consideration
– A new parameter q
– The ratio of the increase in molar reflux F
L V
Feed plate (f)
rate ( L − L ) across the feed stage to the
molar feed rate (F) L V

L −L V −V
q= or q = 1+ Eq 4.1
F F

What is q and how we can calculate it?

- q is the fraction of liquid in the feed
If the vapour fraction is V and liquid fraction is L then the expression
for q is:
L L
q= = Eq 4.2
L+V F

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 Determine the q from Txy diagram
– The vapour and liquid fractions can be determined on the Txy diagram
– Assuming the feed conditions are temperature of T and composition of zF .
The vapour and liquid compositions are yE and xE

V yE
100% L 100% V
T F
zF

L xE
xE zF yE
Total balance: F=V+L or the liquid fraction for feed, q, is:
Ethanol balance: zFF = yEV + xEL L (𝑦𝑦𝐸𝐸 − 𝑧𝑧𝐹𝐹 )
𝑞𝑞 = =
𝑉𝑉 (𝑧𝑧𝐹𝐹 − 𝑥𝑥𝐸𝐸 ) L + V (𝑦𝑦𝐸𝐸 − 𝑥𝑥𝐸𝐸 )
Solve simultaneously to get V/L: Eq 4.3
=
The University of Sydney 𝐿𝐿 (𝑦𝑦𝐸𝐸 − 𝑧𝑧𝐹𝐹 ) Page 7
 The feed operating line (q line)
q-line: connecting the feed and the intersection point between two
operating lines
Intersection point:
L  L
y j +1 = x j + 1 −  xD and y k = L x k −1 −  L − 1 x B
V  V V V 

y (V − V ) = ( L − L) x − ( Dx D + Bx B )
Mass balance: Fz F = DxD + BxB

y (V − V ) = ( L − L) x − Fz F

(V − V ) ( L − L)
y = x − zF ⇒ y (q − 1) = qx − z F
F F
q zF
y=( )x − ( ) Eq 4.4
q −1 q −1
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 Effect of thermal condition of feed on slope of q-line

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 Effect of thermal condition of feed on slope of q-line

– Relationship between feed conditions, q values and q-lines

L −L V −V L V
q= or q = 1 +
F F F Feed plate (f)
(Assumption: flashed adiabatically to the feed stage pressure)

Feed condition q L V
Common feed condition
Subcooled liquid >1
Bubble-point liquid 1
Partially vaporized 0<q<1
Dew-point vapour 0
Superheated vapour <0
(think about what will happen q
slope =
when such feed enter the column) q −1
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Operating lines and q-line on the x-y diagram

Would reflux ratio R change  R   1 

y= x +   xD
the slope of q-line?  R +1  R +1
Would reflux ratio R change the R
slope =
slope of stripping operating line? R +1
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q-line on the x-y diagram - a single flash unit
Partially vaporised
Q. Separation of Hexane-Octane mixture with zH = 0.6, feed
determine phase compositions if 60% is vapourised at
the feed plate?
Solution:
60% feed will vapourise:

L = L + 0.4 F or V = V + 0.6 F

By definition, q =0.4 yH=0.76

Slope of q-line:

q  0.4  2
Slope = = =−
q − 1  0.4 − 1  3

q-line intersect equilibrium

line at point B (xH, yH):
zH=0.6
xH=0.37 and yH=0.76

xH=0.37
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 McCabe-Thiele Graphical Method

– Proposed in 1925.

– The simplest and perhaps most

instructive and straight-forward method
for the analysis of binary distillation.
Warren L. McCabe
– The McCabe–Thiele method determines:
– N, the number of equilibrium stages;
– Nmin, the minimum number of equilibrium
stages;
– Rmin=Lmin/D, the minimum reflux ratio;
– The optimal feed-stage location.

Ernest W. Thiele
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 McCabe-Thiele method – rectification section

– General approach
– Plot the equilibrium curve
– Plot the operating line for
the rectification section

 R   1 
y=  x +  xD
 R + 1  R + 1
– Note that the operating line
intersects the diagonal at
(xD, xD).

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 McCabe-Thiele method – rectification section
– For a total condenser: y1 = xD.  y  1 − x 
α =    ⇒ x1 =
 x  1 − y 
y1
y1 + α (1 − y1 )
(horizontal line, a). The point on
(x1, y1) a
the equilibrium line gives x1, the (xD, xD)
liquid that is in equilibrium with y1 b
(x2, y2)
– Use the operating line to
c
(x0, y2)
(x1, y2)
determine the corresponding d
value of y2 (vertical line, b)
(x1, y3)
– Each step represents an (x2, y3)  R   1 
equilibrium stage in which y j +1 =  x j + 
 R +1
 xD
 R +1
streams entering the stage
reach equilibrium (follow the
stage operating line, green
line) D, x0=xD
Condenser
Draw the line from top to bottom. V1 Reflux ratio, R:
L0
(Remember the tray-by-tray y1 ( Stage 1) x0 R=
L
calculation of the rectifying section) L1
D
V2
y2 x1
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 McCabe-Thiele method – rectification section
Stage operating
D, x0=xD
line, Slope = -L/V
Condenser
(x1, y1) a
V1 L0 Reflux ratio, R: (xD, xD)
y1 ( Stage 1) x0 L
R=
D b
V2 L1 (x2, y2) c
y2 x1 (x0, y2)
(x1, y2)
d Cascade operating
Light component mass balance for (x1, y3)
line, Slope = L/V
stage 1:
(x2, y3)
 R   1 
L0x0 +V2y2 = L1x1 + V1y1 y j +1 =  x j +   xD
 R + 1   R + 1 
L0 = L1 = L & V1 = V2 = V, so:
L(x0 - x1) = V(y1 - y2)

Slope of the operating line, stage 1: (y1 - y2)/(x1 - x0) = - L/V

This also applies to all other stages, why?
Operating line of cascade (rectifying operating line), slope = L/V
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 McCabe-Thiele method – rectification section
– Finally, we will have:

1
2
3
4
5
6

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 McCabe-Thiele method – stripping section

– General approach
– Plot the equilibrium curve
– Plot the operating line for
the stripping section
L L 
y =   x −  − 1 x B
V  V 
– Note that the operating line
intersects the diagonal at
(xB, xB).

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 McCabe-Thiele method – rectification section

– For a partial reboiler the xB is in

equilibrium with the vapour
leaving that stage. Hence draw a
vertical line to determine the
equilibrium vapour composition (xN, yN) d (xN-1, yN)
yN+1.
– Use the operating line to c
determine the corresponding
value of xN (vertical line) (xB, yN+1) b
– Proceed like before (xN, yN+1)
a
Draw the line from bottom to top.
(Remember the tray-by-tray (xB, xB)
calculation of the stripping section)

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 McCabe-Thiele method – stripping section

– Finally, we will have:

N-5
N-4
N-3

N-2
N-1
N

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 McCabe-Thiele method

– Use step-by-step construction

to determine number of
ideal stages
– As intersection of operating Intersection
lines is approached, it must
be decided when the steps
should transfer from the
rectifying line to the
stripping line
– Make the change so that
number of plates is as small
as possible

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 Optimal feed plate location

– The transition from rectification to stripping sections occurs at

the feed stage - switch from one operating line to the other.
– Three conditions

Optimal location: Below optimal stage Above optimal stage

N=5 stages N=6.4 stages N=5.9 stages
After the first horizontal line More rectifying stages More stripping stages
pass over/across point P
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 Impact of relative volatility

– Assuming a constant relative volatility and same operating lines

and q-lines, for various α values:
1 1 1 1
2
11 5 3

5
22 10 4

– Magnitude of α gives an idea of ease of separation.

– α ↑ → easier of separation
System α No. of plates
Water-glycol 200-700 1
Methanol-water 2.5-7.5 30
The University of Sydney P-xylene-m-xylene 1.002-1.018 1000 Page 23
 Impact of reflux ratio R

– Assuming a constant relative volatility and feed condition

(saturated liquid): by varying R value:

N=13 N=9.7

– R ↑, slope of rectifying line ↑, N ↓  R   1 

y= x +   xD
 R +1  R +1
– Increase R will:
R L
• Get more liquid and vapour in column – larger diameter slope = R=
• Less N – height of the column may be reduced R +1 D
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 Limiting conditions

– For the operation of distillation columns 3 limiting conditions can

be studied:
– Total reflux
– Minimum reflux
– Perfect separation
– In practice distillation columns operate with reflux rates that
are bounded by these limiting cases

Total reflux, D=0 Minimum reflux, D≠0

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 Total reflux

– This condition refers to a

situation:
F=B=D=0
– Slopes of both operating lines
will be 1
– This condition gives the minimum
number of theoretical
(equilibrium) stages, Nmin.
– Situation encountered during
start-up, or during shut-downs
of plants.
– To get experimental tray
 R   1 
efficiency. (we will study this in y j +1 =  x j +   xD R→∞
 R +1  R +1
distillation practical)
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 Minimum reflux

– Refers to the minimum reflux,

(L/V)min (or Rmin), needed to
effect a given separation with
infinite number of stages.
– The point where the operating
line and equilibrium curve meet
is termed as the “pinch point”.
– Requires infinite plates to
achieve separation.
– (L/V)min is usually used to
specify operating conditions.
From the diagram, the slope of the operating
line under this condition is Rmin

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 Perfect separation
– A perfect separation:
xD=1 and xB=0
Pinch point
– Requires infinite plates to achieve (xP, zF)
separation.
– R? (for R > Rmin)
– q?
– Rmin for perfect separation
q=1
Example: saturated liquid feed: q=1
Find the slope on the line connecting the
pinch point and point (1,1)
For phase equilibrium:
αx αz F
y= x = zF yP =
1 + x(α − 1) 1 + z F (α − 1)
For rectifying operating line slope:
 R   1  R
y= x +   xD slope =
 R +1  R +1 R +1
Rmin 1 − yP
= slope =
Rmin + 1 1 − zF
From the diagram, the slope of the
Rmin = 1 operating line under this condition is Rmin
z F (α − 1)
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 Choice of reflux ratio – Thumb rule

– Usually, R is chosen to be 1.1~1.5 Rmin

– e.g. “A column is operated with a reflux 1.2 times that of the
minimum.....”
– Impact of R on the column design
R=Rmin : infinite stage number, infinite tall column;
Increase R:
1. Operation cost increase;
2. Instrument cost will also change;

A optimal R can be located

R ≈ (1.3 −1.5) RMIN

N ≈ 2 N MIN

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 Example
– Q. Separation of a Benzene-Toluene mixture. Assume a constant α=2.5. F = 450
kmol/hr, xF=0.6. Expecting xD=0.95 and xB=0.1.(1) Feed enters the column with a
molar percent vaporisation equal to the distillate-to-feed ratio.(2) Use McCabe-
Thiele method to find at 1 atm, (a) Nmin, (b) Rmin and (c) number of equilibrium stages
(N) for R/Rmin=1.3 and the optimal feed-stage location.
– Solution
– (a) Find Nmin: slopes of two operating line equal to 1, use graphical method
– Draw the equilibrium curve;
– Follow the McCabe-Thiele method from distillate point.

Result Nmin=5.8

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 Example

– Solution (cont.) Slope=Rmin/(Rmin+1)

– (b) Find Rmin: slope of the operating line connecting the pinch
point and point (xD, xD)
– From condition (1), calculate D and B from mass balance:
Benzene xF × F = x B × B + x D × D 0.6 (450) = 0.95D + 0.1B B = 256
Overall D+B=F 450 = D + B D = 194

– From condition (2), VF/F = D/F = 194/450 = 0.431, so by

definition of q:
L − L LF V
q= = = 1 − F = 1 − 0.431 = 0.569
F F F
– Slope of q-line:
q 0.569
slope = = = −1.32
q − 1 0.569 − 1

– q-line passes point (xF, xF) and intersect with equilibrium line: 1. How to find the pinch point?
Intersection of q-line and
q z αx Solve this equation, equilibrium line
y=( )x − ( F ) = y =
q −1 q −1 1 + (α − 1)x P (0.507, 0. 720) 2. From the diagram, the slope
– Slope of rectifying line of the operating line under
this condition is Rmin.
Slope=Rmin/(Rmin+1)=0.519, so Rmin = 1.08

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 Example
– Solution (cont.)
– (c) Find equilibrium stage number N
and optimal feed plate when R = 1
1.3Rmin:
– Operating at: R = 1.3Rmin = 1.4
5
– For the operating line: y = 0.583x+0.396 6
– Draw on the x-y diagram
7

– For the q-line: (will the q-line

change?)
– Find the intersection and draw the
stripping line by connecting point (xB,
xB) and the intersection point.
11
– Use McCabe-Thiele method
N=11
– Decide optimal feed stage:
6th plate from top

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