University of Khartoum

Facultyof

EngineeringChemical Engineering

Deparmentt

Tray DistillationColumnDesignAssignment
By: Roaa Abdulaziz 182025
Sahar jalal 182035
Afaf shaihk Aldeen 182044

- BriefIntroduction:
A mixture of Benzene and toluene can be separated using a distillation column
,the separation is caused by the heat added to the column which causes
thefractionationof components.
BothsubstancesobeyRaoult'slaw.

-Theory
Therearetwomain stepsin thedesignprocedure:

1. Finding the required reflux ratio and number of stages byMcCabe-

Thielemethod

2. Columndiameterandtrayhydraulicdesigncalculationsandchecks.

ForMcCabe-Thielemethodthefollowingassumptionsandstepsareused:

1. Theflowratesofliquid andvapor are assumed to be

constantthroughoutthe column.
2. Theq is calculated.
3.
4. Theequilibrium curveis plotted formthegivendatain thenextsection.
5. The45⁰ lineisplotted.
6. Theequilibriumstagesaresteppedoff,andNminis determined.
7. AstraightlinethatpassesthroughxBand pinchpoint,is
drawn,fromitsintersectionwiththey-axis,Rminis determined.
8. Riscalculated.
9. TheL,L,VandV.
10. Therectifyingandthestrippingoperatinglinesarewritten.
11. Thepoint(xF,yF),isfound.
12. Theequilibriumstagesarestepped off,andNidealisdetermined.
13. Thefeedenteringstageisdeterminedfromtheplot.
14. TheE0iscalculatedusingO’Connellcorrelation.
15. TheNactualcalculated..

-Data:
 1. ColumnSpecifications(feed,distillate,bottomsconditions )
Benzene=LK,Toluene=HK.
FeedFlowRate 100kmol/hr

FeedComposition Benzene60%

Toluene40%
Columnoperatingpressure Atmospheric
(1atm)
Columncondenser Totalcondenser
Columnreboiler Partialreboiler
Distillatecomposition 90% Benzene
10%Toluene
Bottomcomposition 10%Benzene
90%Toluene

2. PhysicalProperties:
Compound 𝑀𝑤𝑖
Benzene 78.114
Toluene 92.141

𝑀𝑤𝑎𝑣𝑒=0.6∗78.114 + 0.4 ∗ 92.141=83.72

i. Viscosity:

Compound 𝜇𝑎𝑣𝑒(𝑐𝑃)
Benzene 0.26
Toluene 0.27
 ii. Density:

Density of mixture =870kg/m^3

𝑃𝑉=𝑛𝑅𝑇
Assume 100mm tolune :
Coloumn p drop =100 *10 ^-
3*9.81*11*844=9107.6pa
Top pressure =101.4*10^3pa
Bottom pressure =110507.6 pa

From steam table T=108°c

𝜌𝑣=3.6 kg/m^3
𝜌l =860 Kg/m^3

𝜎=0.0284
At T=80°c
𝜌𝑣=3 kg/m^3
𝜌l= 874 kg/m^3
𝜎 = 0.0288
 3. EquilibriumData:
x y

1.000 1.000
0.908 0.962
0.817 0.919
0.731 0.874
0.651 0.825
0.575 0.773
0.504 0.717
0.437 0.657
0.373 0.594
0.313 0.527
0.256 0.456
0.203 0.380
0.152 0.300
0.103 0.215
0.057 0.125
0.013 0.031
0.000 0.000

DesignCalculations:
Overall material balance:𝐹=𝐷+𝐵
Overallcomponentbalance:

Tf=92.3°c
𝑥𝐹𝐹=𝑥𝐷𝐷+𝑥𝐵𝐵
0.6×100=𝐷+ 𝐵
0.6×100=0.9𝐷+ 0.1𝐵
D=62.5kmol/h. , B=73.5kmol/hr.
McCabe-Thielemethod:
Assume q=1
 Nmin=5stages, takeitas
6.4stageFromthegraph:

Rmin=0.58

Theoptimalrefluxratio iswithin therangeof 1.1-1.5ofRmin.let R ratio =1.5

R=0.868

𝐿=𝑅𝐷=0.868∗ 62.5= 54.25kmol/h

𝐿=𝑅𝐷+ 𝐹=0.868∗62.5+ 100= 154.25kmol/h

𝑉=𝑉=(𝑅+1)𝐷=(0.868 +1)*62.5=116.75kmol/h

Slope of bottom :
0.76 -0.1
_________ =1.32
0.6-0.9

Slope of top :
0.89 -0.76
_________ =0.5
0.9-0.6
AtxF,yF=0.639.
Fromthegraph:
Nideal=8.5.
O’Connellcorrelation:
Theoverallefficiencycouldbefoundby
𝐸0=50.3(𝛼𝑎𝑣𝑒𝜇)−0.226 ,0.1≤ 𝜇≤ 10𝑐𝑃.

Or byusingchartin page277of [4].

𝐸0=70%

But,
𝑁
𝐸0 = 𝑁𝑖𝑑𝑒𝑎𝑙
𝑎𝑐𝑡𝑢𝑎𝑙
𝑁𝑖𝑑𝑒𝑎𝑙 =12.1
‫؞‬ = =8.5=12.1 stage
𝑎𝑐𝑡𝑢𝑎𝑙 𝐸0 0.70

1. Platehydraulicdesign:
136.916∗85.83
VW= =3.26 𝑘𝑔/𝑠
3600
Vv= 3.26 =1.2m3/s
2.716
201.744∗85.83
LW= =4.18𝑘𝑔/𝑠
3600

L 4.18 =0.006m3/s
vl=_______
800
i. Diameter:
the column diameter must be selected so that that flooding does not occur
and

the velocity will normally be between 70 to 90 percent of that which would

cause

flooding.

Flooding is brought about by excessive vapor flow, causing liquid to be

entrained in

the vapor up the column. The increased pressure from excessive vapor also
backs up

the liquid in the down-comer, causing an increase in liquid holdup on the

plate above.

Depending on the degree of flooding, the maximum capacity of the column

may be

severely reduced. Flooding is detected by sharp increases in column

differential

pressure and significant decrease in separation efficiency.The flooding

vapor velocity

is calculates by below equation

ρι−ρν
𝑈𝑓=K1√
ρν
 𝐿𝑤 𝜌𝑣
𝐹𝐿𝑣= √
𝑉𝑤 𝜌𝑙

Lw = liquid mass flow rate

Kg/sVw=vapormass
flowrateK/s

Vm=Vapourmassliquid

=VMw=[1167.5*83.72]/3600=
2.71

L=RD+F=154.25
Lm=Lmw=[154.25*83.72]/360
0=3.6

Flv = 0.09. K1=9×10^-2

Uf =1.4m/s

U^v=1.4
×flooding%=1.4×85%=1.2m/

To calculate the column diameter an estimate of the net area An is required

takethe downcomer area as 12 per cent of the total, and assume that the hole
activeareais 10percent
 volumetric =2.7/3.6=0.75
An =volumetric date/u^v =
0.63 m^2
Ac=An/0.88=
0.7
Dc=0.95 m
Ad=0.12Ac=0.084 m^2
Aa=Ac-2Ad=0.532m^2
An=0.1Aa =0
.053
(Ad/Ac)×100=12
Lw/Dc= 0.76
Lw=0.76*0.95=0.722m

ii. Liquid-flowarrangement:

The choice of plate type (reverse, single pass or multiple pass) will depend on
theliquid f low-rate
.andcolumndiameter
Aninitialselectioncanbemadeusingfigure11.28 [2].

iii. Entrainment:

Canbeestimatedfromthecorrelationgiven byfigure11.29[2]givesthe
fractional entrainment ѱ (kg/kg gross liquid flow) as a function of the liquid-
vaporfactorwith thepercentageapproachto floodingasparameter
Thepercentagefloodingisgivenby:

𝑈𝑛𝑎𝑐𝑡𝑢𝑎𝑙𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦(𝑏𝑎𝑠𝑒𝑑𝑜𝑛𝑛𝑒𝑡 𝑎𝑟𝑒𝑎)
Percentageflooding= 𝑈𝑓(𝐹𝑜𝑒𝑚𝑒𝑞𝑢𝑎𝑡𝑖𝑜𝑛11.81)
85%
Theupperlimit of
ѱcanbetakenas 0.04
<0.1
Weir liquid crest :

Weir is small dam used to hold up the liquid on the tray. Weir crest is the height

of the liquid crest over the weir and can be estimated using the Francis Formula.

how=24.2mm
Minimum liquid rate at 70%=
0.7 *3.6=2.5kg/s
how (min)= 19.1mm
hw +how =69
from gragh: K2=30.2

:Preforted Area
From figure 11.32 at Lw/Dp=. 75
Seta=99c
angle Subtended at plate edge by unperforted Strip=180 -99=81c
Mean Lenght, unperforted edge Strip=(. 95_.05) *bi 81/180=1.3m
Area for unperforted edge strip=. 05*1.3=.065
Mean lenght of calming zone=(. 95_5)*sin(99/2)=.624m
Area of calming zone=2(.624*50*10^-1)=. 624m^2
total area of prefortaion, Ap=. 53-.65-.0624=. 403m^2
Ah/Ap=13
From figure 11.33 lp/dh= 2.7 satisfactory, Wthin 2.5 to 4
iv. Check weeping :
vapors 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 by a sharp

pressure drop in

the column and reduced separation efficiencyThe vapor velocity at the

weep point is the minimum value for stable operation. The

hole area must be chosen so that at the lowest operating rate the vapor
flow velocity is

still well above the weep point.

The minimum design vapor velocity is given by:

[𝐾2−0.90(25.4−𝑑ℎ)]
ŭℎ= =

𝜌𝜈1/2
=6.2m/s
U min (act )=[0.7 *volumetric ]/Ah
=9.9m/s
 v. Weirliquidcrest:
Canbeestimatedusingthe Francisweirformula
The height of the liquid crest will be higher than that predicted the crest
shouldbeatleast10mmatthelowestliquid rate

𝐿𝑤 2/3
ℎ𝑜𝑤=750[ ]
𝜌𝐿𝑙𝑤
lw =weir length,m-how =weir crest,mm -liquidLw=liquidflow rateKg/s

vi. Weirdimensions:

Weir height
The height of the weir determines the volume of liquid on the plate and is
animportantfactor indeterminingtheplateefficiency.
Ahigh weirwill increasetheplateefficiency.
For columns operating above atmospheric pressure the weir heights between
40mmto 90mm(1.5to3.5in.);40to50mmis recommended.
Forvacuumoperation lowerweir heightsareused
toreducethepressuredrop;6to12mmis recommended.

Weir height =50mm

vii. Inletweirs

Inlet weirs or recessed pans used to improve the distribution of liquid across
theplate
 viii. Weirlength:

Thelength oftheweirfixestheareaof thedowncomer.

Thechord lengthwillnormally
bebetween0.6to0.85mmofthecolumndiameter.
Agood initialvalueto useis 0.77,equivalent toadowncomerareaof 12percent

ix. Holesize:

The hole sizes used vary from 2.5 to 12 mm; 5 mm is the preferred size. Larger
holes
Hole size =5mm

are occasionally used for fouling systems. The holes are drilled or punched.
Punching

is cheaper, but the minimum size of hole that can be punched will depend on
the plate

thickness, For carbon steel, hole sizes approximately equal to the plate be
punched, but for stainless steel the minimum hole size that can be punched is
about twice the plate thickness
Plate thickness =5mm

x. Holepitch:

The hole pitch (distance between the hole centers) should not be less than 2.0 hole

diameters, and the normal range will be 2.5 to 4.0 diameters. Within this range the

pitch can be selected to give the number of active holes required for the total hole
area

specified. Square and equilateral triangular patterns are used; triangular is preferred.

The total hole area as a fraction of the perforated area

Ap is given by the following

expression equation for an equilateral triangular pitch equation

Thisequationisplottedin Figure11.33[2].

xi. Dryplatedrop
Maximum vapour velocity =0.75/0.05 =15
The pressure drop through the dry plate can be estimated using expressions:
𝑈ℎ 2𝜌𝜈
ℎ𝑑=51[ ] 𝜌𝐿
𝐶₀ =68.1mm

C₀=orificecoefficient
C₀Can beobtained fromFigure11.34[2].

xii. Residualhead:

12.5×103
ℎ𝑟=
𝜌𝐿
=14.5
xiii. Totaldrop:

ℎ𝑡=ℎ𝑡+(ℎ𝑤+ℎ𝑜𝑤) +ℎ𝑟 =156.8mm

xiv. Downcomerdesign:

ℎ𝑏=(ℎ𝑤+ ℎ𝑜𝑤)+ ℎ𝑡+ℎ𝑑𝑐=

Where
hb=downcomerback-up mm
hdc=head less inthedowncomermm

𝐿𝑤𝑑
ℎ𝑑𝑐=166[ ]
𝜌𝐿𝐴𝑚
=3.2mm

Lwd = liquid flow rate in the downcomer

Kg/sAm=either thedowncomerareaAd𝑚2

𝐴𝑎𝑝=ℎ𝑎𝑝𝑙𝑊 =0.04 *0.723= 0.03

hap = is height of the bottom edge, and from 5 to 10 mm below the outlet
weirheight

ℎ𝑎𝑝=ℎ𝑊−(10𝑚𝑚) =40mm

xv. Frothheight:
.

1
ℎ𝑏𝑘 (𝑙𝑡+ℎ𝑊 )
2

xvi. Downcomerresidencetime:

𝐴 𝑑ℎ 𝑏𝑐𝜌𝐿 >3sec
𝑡𝑟 =
𝐿 𝑤𝑑
 tr=residencetime,s hbc=clear liquidback-up,m.

tr =4.7 >3sec

xvii. Platepressuredrop:
∆𝑝𝑡=9.81×10−3ℎ𝑡𝜌𝐿

Δpt=totalpressuredrop,Pa.
ht=totalpressuredrop,mm liquid.
:dry pressure drop
=Maximum vapour volicity Um
hd=51(Um/2.84)*(dv/dl)B =68.1mm
(dv,dl)B=dinsity of vapour and liquid in The Bottom
hr=12.5*10^3/dl=14.5
h+hr+hd+how+hw=14.5+24.2+50+68.11=156.8mm
: down column liquid
:down colum pressure loss
take hap=hw-10=40mm
Ap=hap*lw=. 04*.772=. 03mm
hdc=166(lm/dl*Al)^2=3.2mm
(05.-5 .)<hp=hd+hw+how+hdc=234.2
.275 .>234
xviii. Hydraulicgradient

Thehydraulicgradientis usuallyignoredin-sieveplatdesign.

xix. Numberofholes:
Areaof onehole= 𝜋 ∗ 𝑑 2
4 ℎ
𝑇𝑜𝑡𝑎𝑙𝑎𝑟𝑎𝑒 𝑜𝑓ℎ𝑜𝑙𝑒
Numberof holes=
𝐴𝑟𝑒𝑎𝑜𝑓𝑜𝑛𝑒ℎ𝑜𝑙𝑒
=2704 holes
xx. Heightofcolumn:

Hc=(Nactual-1)*Trayspacing+∆𝐻+Nactual*platethickness.

=6.6 =7m
xxi. Plateareas :
Thefollowingareaterms areused intheplatedesignprocedure:

A. Ac=totalcolumncross-sectionalarea.
B. Ad=cross-sectionalareaof downcomer(=12%Ac).
C. An = net area available for vapor-liquid disengagement, normally equal
toAc–2Adforasinglepass plate.
D. Aa = active or bubbling area equal Ac – 2Ad for
singlepassplate.
E. Ah =holearea,thetotalareaofalltheactiveholes (=10%Aa).
F. Ap=perforatedarea(includingblanked area).
G. Aap=theclearanceareaunderthedowncomer apron.
Theinitial guessesused inthedesign:

Trayspacing 0.5m
dh 5mm
hw 50mm
lw 0.77dh=0.913mm
lP 4dh=20mm
Thicknessofplate 5mm
Turndown 70%ofmaxflow rate
Holepitch Triangular

75mm

75mm
40mm
0.913mm
1.186m

50mm

-ResultsofCalculations:
Afterseveralalteration,theresultscouldbesummarizedasfollowing:

L 54.24kmol/h
L 154.24kmol/h
V=V 116.75kmol/h
𝑁𝑚𝑖𝑛 5
𝑁𝑖𝑑𝑒𝑎𝑙 8.5
 𝑁𝑎𝑐𝑡𝑢𝑎𝑙 11
Flowliquidpattern Singlepass
Feedenteringstage 4
Columndiameter,Dc 0.95m
Columnheight 7m
Flooding velocity, 1.4m/s
uf(SGV)
Actual velocity, 1.2m/s
uactual(SGV)
Percentageflooding 80%
Weeping velocity, 6.2m/s
uf(VTH)
Actual velocity, 9.9m/s
uactual(VTH) (≥7.427m/s)
Pressuredropperplate 15mmliquid
Totalcolumnpressure 15127.67Pa
drop
Downcomerliquid 183.233mm
(<275 𝑚𝑚)
Trayresidencetime 4.7s (>3𝑠)
Fractionalentrainment 0.04(≤0.1)
Numberofholes 2704
Columnarea 0.7m2
Downcomerarea 0.084
Activearea 0.532m2
Totalholearea 0.053m2

-References:
1. R.K.Sinnott,Coulson&Richardson'sChemicalEngineeringVolume6.
2. J.D.Seader&E.J.Henley,SeparationProcessPrinciples.