1

A Presentation on Distillation Tower

& Plate Contactors in Distillation
Tower
Supervisor

Prof. Dr. H M Anwaar Asghar
Presentors
M. Haris Hamayun
M. Ishtiaq Qasim
Usman Khalid
M. Adil Maqsood
Junaid Ilyas
2
3
Simple Distillation Methods
Introduction
Distillation is a method used to separate the components of liquid solution,
which depends upon the distribution of these various components between
a vapor and a liquid phase.

The vapor phase is created from the liquid phase by vaporization at the
boiling point.

Distillation is concerned with solution where all components are appreciably
volatile such as in ammonia-water or ethanol-water solutions, where both
components will be in the vapor phase.
4
Relative Volatility of Vapor-Liquid Systems
) 1 )( 1 (
/
/
/
A A
A A
B B
A A
AB
x y
x y
x y
x y

= = o
A AB
A AB
A
x
x
y
) 1 ( 1 +
=
o
o
P
x P
y
A A
A
=
B
A
AB
P
P
= o
P
x P
y
B B
B
=
Relative volatility
It is a measure of the differences in volatility between 2 components, and hence their boiling
points. It indicates how easy or difficult a particular separation will be.
Where
AB
is the relative volatility of A with respect to B in the binary system.
when
AB
is above 1.0, a separation is possible.
Raoults law:
) (
AB
o
5
Types of Distillation
Distillation has two main methods in practice.
1. Without Reflux (Flash Distillation)
2. With Reflux(fractional distillation, distillation with reflux, or
rectification).
There are 3 important types of distillation that occur in a single stage or
still:
Equilibrium or flash distillation
Simple batch or differential distillation
Simple steam distillation
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Equilibrium or Flash Distillation
Flash distillation is a single stage separation technique.
1. Pumping of feed to increase its temperature & enthalpy.
2. Pressure reduction through a valve causing partial vaporization.
3. Once the mixture enters a big enough volume (the flash drum), the liquid and
vapor separate.
4. Because the vapor and liquid are in such close contact up until the flash occurs,
the product liquid and vapor phases approach equilibrium.
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Equilibrium or Flash Distillation
heater
Separator
Total mass balance:
Component A balance:

where
F, V and L are flow rate of feed, vapor and liquid phases.
x
F
, y
A
and x
A
are mole fraction of component A in feed, vapor and liquid.
A A F
x f y f x ) 1 ( + =
Where
f = V/F = molal fraction of the feed that is vaporized and withdrawn continuously as vapor.
1-f = one as liquid
Material balance for more volatile component :

x
A
y
A
A A F
x
F
V
F
F
y
F
V
x ) ( ) ( + =
A A F
Lx y V Fx + =
L V F + =
8
Simple Batch or Differential Distillation
The pot is filled with liquid mixture and
heated.

Vapor flows upwards though the column and
condenses at the top.

Part of the liquid is returned to the column as
reflux, and the remainder withdrawn as
distillate.

Nothing is added or withdrawn from the still
until the run is completed.
Sections of Continuous Distillation
Columns
A typical distillation contains several
major components:
-A Vertical shell.

-Column internals.

-Re-boiler.

-Condenser.

-Reflux drum
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Introduction to Distillation with Reflux
1. Feed enters the column somewhere in
the middle of the column.
5. The vapor continues up to the next tray
or stage, where it is again contacted with
a downflowing liquid.
2. Feed is liquid, it flows down to a sieve
tray or stage.
4. The vapor and liquid leaving the tray
are essentially in equilibrium.
3. Vapor enters the tray and bubbles
through the liquid on this tray as the
entering liquid flows across.
6. The concentration of the more volatile
component is being increased in the vapor
form each stage going upward and
decreased in the liquid from each stage
going donwards.
11
Introduction to Distillation with Reflux
7. The final vapor product coming
overhead is condensed in a condenser
and a portion of the liquid product
(distillate) is removed, which contains a
high concentration of A.
9. The liquid leaving the bottom tray
enters a reboilier, where it partially
vaporized, and the remaining liquid, which
is lean in A or rich in B, is withdrawn as
liquid product.
8. The remaining liquid from the
condenser is returned (refluxed) as a
liquid to the top tray.
10. The vapor from the reboiler is sent
back to the bottom stage or trays is much
greater.
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McCabe-Thiele Method of Calculation for Number of
Theoretical Stages
A mathematical graphical method for determining the number of theoretical
trays or stages needed for a given separation.

Uses material balances around certain parts of the tower, which give
operating lines and the xy equilibrium curve for the system.

Main assumption
1) Equi-molar overflow through the tower between the feed inlet and the top tray
and the feed inlet and bottom tray.

2) Liquid and vapor streams enter a tray, are equilibrated, and leave.
Introduction and assumptions
13
A total material balance:
n n n n
L V L V + = +
+ 1 1
A component A balance:
n n n n n n n n
x L y V x L y V + = +
+ + 1 1 1 1
Where
V
n+1
is mol/h of vapor from tray n+1
L
n
is mol/h liquid from tray n
y
n+1
is mole fraction of A in V
n+1
and so on.

14
A total material balance:
A component A balance:
Where
F is the entering feed (mol/h)
D is the distillate (mol/h)
W is the bottoms (mol/h)
W D F + =
w D F
Wx Dx Fx + =
Equation for Enriching Section/ Rectification Section
(1)

(2)

15
Material balance over dashed-line section: D L V
n n
+ =
+1
A balance on component A:
D Dx x L y V
n n n n
+ =
+ + 1 1
(4)

(3)

16
Solving for y
n+1
, the enriching-section operating line is
) 1 /( / ,
1 1
+ = + =
+ +
R R V L D L V
n n n n
D L R
n
/ =
1 1
1
+
+
+
=
+
R
x
x
R
R
y
D
n n
where = reflux ratio = constant.
The eqn. (1) is a straight line on a plot of vapor composition versus liquid
composition.

Since and equation becomes
1 1
1
+ +
+
+ =
n
D
n
n
n
n
V
Dx
x
V
L
y
(6)

(5)

17
Equation for stripping section
Material balance over dashed-line section: W L V
m m
=
+1
A component A balance: w Wx x L y V
m m m m
=
+ + 1 1
(8)

(7)

18
Solving for y
m+1
, the enriching-section operating line is
1 1
1
+ +
+
=
m
W
m
m
m
m
V
Wx
x
V
L
y (9)

1 +
=
m m
V L
Again, since equimolal flow flow is assumed, = constant and
= constant, eqn. (2) is a straight line when plotted as y versus x,
with a slope of . It intersects the y = x line at x = x
w
.
The intercept at x = 0 is .
N m
L L =
N m
V V =
+1
1
/
+
=
m W
V Wx y
19
The theoretical stages for the stripping section are determined by starting at
x
W
, going up to y
W
, and then across to the operating line, etc.
20
Effect of feed conditions
The condition of feed stream is represented by the quantity q, which is the mole
fraction of liquid in feed.
qF L L
n m
+ =
F q V V
m n
) 1 ( + =
D n n
Dx x L y V + =
w m m
Wx x L y V =
) ( ) ( ) (
w D n m n m
Wx Dx x L L y V V + =
The enriching and striping operating-line
equations on an xy diagram can be
derived as follows:
Where the y and x values are the point of
intersection of the two operating lines.
Subtracting eqn.(12) from eqn.(13),
(12)
(13)
(14)

(10)
(11)

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Effect of feed conditions
Substituting eqn.(2), (10), and (11) into eqn.(14) and rearranging,
(15)

1 1

=
q
x
x
q
q
y
F

) (
1
F b pL
T T c
q

+ =

) (
1
d F pV
T T c
q

+ =
Cold-liquid feed Superheated vapor
where
C
pL
, C
pV
= specific heats of liquid and vapor, respectively
T
F
= temperature of feed
T
b
, T
d
= bubble point and dew point of feed respectively
= heat of vaporization
Sub-cooled
Liquid (q>1)
Sat liquid (q=1)
Vapr/liq mixture (0<q<1)
Saturated vapor (q=0)
Superheated
Vapor (q<0)
Feed condition


Designing Steps of Distillation Column

Calculation of Minimum number of stages N
min

Calculation of Minimum Reflux Ratio R
m
.

Calculation of Actual Reflux Ratio.

Calculation of theoretical number of stages.

Calculation of actual number of stages.

Calculation of diameter of the column.

Calculation of weeping point, entrainment.

Calculation of pressure drop.

Calculation of the height of the column.
1
st
point
2
nd
point
3
rd
point
n = 7 =number of tray + reboiler
Number of tray = 6
Number of stages and trays
Stage construction
Y-intercept
x
d
/R+1

(x
d
, y
d
)

(x
f
, y
f
)
(x
b
, y
b
)
Sat vapour
1
6
5
2
4
3
Slope = R/(R+1)
Slope = q/(1-q)
Slope = L/ V
Using Operating Lines and the Feed Line in McCabe-Thiele Design
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4.4.4C Operating and optimum reflux ratio
Total reflux = number of plates is a minimum, but the tower diameter is infinite.
This corresponds to an infinite cost of tower and steam and cooling water. This
is the limit in the tower operation.
Minimum reflux = number of trays is infinite, which again gives an infinite cost.
These are the two limits in operation of the tower.
Actual operating reflux ratio to use is in between these two limits. The optimum
reflux ratio to use for lowest total cost per year is between the minimum R
m
and
total reflux (1.2R
m
to 1.5R
m
).
Calculation of Minimum Reflux Ratio R
m
:
Using Underwood equations



As feed is entering as saturated vapors so,

q = 0

By trial, u = 1.68


Using equation of minimum reflux ratio,

Putting all values we get,
R
m
= 4.154
Actual Reflux Ratio:
The rule of thumb is:
R = (1.2 ------- 1.5) R
min
R = 1.5 R
min

Theoretical no. of Plates:
(

|
.
|

\
|
+

=
+

566 . 0
min min
1
1 75 . 0
1 R
R R
N
N N
Calculation of actual number of stages:
Overall Tray Efficiency:


(

|
|
.
|

\
|
=
avg avg o
E o . log 5 . 32 51

avg
=average relative volatility of light key component


avg
= molar average liquid viscosity of feed evaluated at
average temperature of column
Types of contactors
Bubble cap Tray
Valve Tray
Sieve Tray

Bubble Cap
Sieve tray
Valve tray
Generally, trays are made of stainless steel, e.g. Type
304, 316 or 410

The main factors affecting the choice of materials of
construction of tray parts are:
Material of construction
Compatibility with the chemicals processed
Compatibility with the column materials of
construction
Anticipated rate of corrosion
Procedure and expected frequency of cleaning
Cost (e.g. maintenance, replacement, effects on plant
operations, etc)

The function of a tray is to facilitate contact between
the vapour phase and liquid phase so that mass transfer
between the 2 phases can take place
Tray Column

The function of a weir is to maintain a desired liquid
level on the tray
Function of weir
Function of downcomers
Weir and downcomers
Bubble cap consists of a slotted cap on a central riser
Bubble cap Tray
The gas flows up through the riser, reverse flow under
the cap, passes downward through the annulus
between riser and cap, and finally passes into the
liquid through a series of openings or "slots" in the
lower side of the cap.
Bubble cap
Because of its high cost and complexity, most modern
column designs favour the use of sieve or valve trays
over bubble-cap trays
Bubble-caps should only be used where very low
vapour rates have to be handled.
Limitations of bubble cap tray
A valve tray is a flat perforated plate, with each
perforation fitted with a movable disk (the "valve)
Valve tray
Types of Valves


weeping may result if excessive valve opening occurs
prematurely
weeping
..\Documents\Valve2.html
Valve tray
Valve tray
In the sieve trays the vapour passes through a large
number of "holes" known as perforations (sieves) and
emerges through the liquid in a vertical direction as shown
in the diagram
Sieve tray

The sieve tray has the simplest design among the
various tray types.
There are no mechanical moving parts.
There is no seal for liquid except the vapours that
effectively prevents the loss of liquid through the
sieves
Design of sieve tray
It occurs when there is low vapor flow and/or high liquid
rates when the liquid height on the tray exceeds the tray
pressure drop.
weeping
Typical layout for sieve tray follows either a square
hole pitch or equilateral triangular hole pitch.
Hole pitch is the centre-to-centre hole spacing.
Typical sieve sizes used industrially range from as
small as 1/16-inch to 1-inch.

Layout for sieve trays
Cost
Operating range
Pressure drop
Maintenance

Selection criteria

Selection Criteria